Yfm400fwa 2000 5gh3ae1

YFM400FWA(M ) 2000
5GH3-AE1
SERVICE MANUAL
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YFM400FWA(M) 2000
SERVICE MANUAL
1999 by Yamaha Motor Co., Ltd.
First Edition, July 1999
All rights reserved. Any reproduction or
unauthorized use without the written
permission of Yamaha Motor Co., Ltd.
is expressly prohibited.

EB001000
NOTICE
This manual was produced by the Yamaha Motor Company primarily for use by Yamaha
dealers and their qualified mechanics. It is not possible to include all the knowledge of a
mechanic in one manual, so it is assumed that anyone who uses this book to perform mainte-
nance and repairs on Yamaha machine has a basic understanding of the mechanical ideas
and the procedures of machine repair. Repairs attempted by anyone without this knowledge
are likely to render the machine unsafe and unfit for use.
Yamaha Motor Company, Ltd. is continually striving to improve all its models. Modifications
and significant changes in specifications or procedures will be forwarded to all authorized
Yamaha dealers and will appear in future editions of this manual where applicable.
NOTE:
Designs and specifications are subject to change without notice.
IMPORTANT INFORMATION
Particularly important information is distinguished in this manual by the following notations.
The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR
SAFETY IS INVOLVED!
WARNING Failure to follow WARNING instructions could result in severe injury or
death to the machine operator, a bystander or a person inspecting or
repairing the machine.
CAUTION: A CAUTION indicates special precautions that must be taken to avoid
damage to the machine.
NOTE: A NOTE provides key information to make procedures easier or clearer.

EB002000
HOW TO USE THIS MANUAL

MANUAL ORGANIZATION
This manual consists of chapters for the main categories of subjects. (See “Illustrated sym-
bols”)
1st title 1: This is the title of the chapter with its symbol in the upper right corner of each
page.
2nd title 2: This title indicates the section of the chapter and only appears on the first page of
each section. It is located in the upper left corner of the page.
3rd title 3: This title indicates a sub-section that is followed by step-by-step procedures
accompanied by corresponding illustrations.
EXPLODED DIAGRAMS
To help identify parts and clarify procedure steps, there are exploded diagrams at the start of
each removal and disassembly section.
1. An easy-to-see exploded diagram 4 is provided for removal and disassembly jobs.
2. Numbers 5 are given in the order of the jobs in the exploded diagram. A number that is
enclosed by a circle indicates a disassembly step.
3. An explanation of jobs and notes is presented in an easy-to-read way by the use of symbol
marks 6. The meanings of the symbol marks are given on the next page.
4. A job instruction chart 7 accompanies the exploded diagram, providing the order of jobs,
names of parts, notes in jobs, etc.
5. For jobs requiring more information, the step-by-step format supplements 8 are given in
addition to the exploded diagram and the job instruction chart.

EB003000
1 2 ILLUSTRATED SYMBOLS
GEN Illustrated symbols 1 to 0 are printed on
INFO SPEC the top right of each page and indicate the
subject of each chapter.
3 4
1 General information
INSP 2 Specifications
ADJ ENG 3 Periodic inspections and adjustments
4 Engine
5 6 5 Cooling system
6 Carburetion
COOL CARB 7 Drive train
8 Chassis
9 Electrical
7 8
0 Troubleshooting
DRIV CHAS
9 0
– + TRBL
ELEC SHTG
A B Illustrated symbols A to H are used to
identify the specifications appearing in the
text.
A Can be serviced with engine mounted
C D B Filling fluid
C Lubricant
D Special tool
E Torque
F Wear limit, clearance
E F
G Engine speed
H Ω, V, A
T.
R.
G H
I J K Illustrated symbols I to N in the exploded

diagrams indicate the types of lubricants
and lubrication points.
E G M
I Apply engine oil
L M N J Apply gear oil
K Apply molybdenum disulfide oil
B LS M L Apply wheel bearing grease
M Apply lightweight lithium-soap base grease
N Apply molybdenum disulfide grease
O P
Illustrated symbols O to P in the exploded
diagrams indicate where to apply a locking
LT
New agent O and when to install a new part P.
O Apply the locking agent (LOCTITE )
P Replace

TABLE OF CONTENTS
GENERAL INFORMATION GEN
INFO 1
SPECIFICATIONS SPEC 2
PERIODIC INSPECTION AND
INSP
ADJUSTMENTS ADJ 3
ENGINE ENG 4
COOLING SYSTEM COOL 5
CARBURETION CARB 6
DRIVE TRAIN DRIV 7
CHASSIS CHAS 8
– +
ELECTRICAL ELEC 9
TROUBLESHOOTING TRBL
SHTG 10

GEN
INFO 1
GEN
INFO
CHAPTER 1.
GENERAL INFORMATION
MACHINE IDENTIFICATION .........................................................................1-1

VEHICLE IDENTIFICATION NUMBER ..................................................1-1
MODEL LABEL ......................................................................................1-1
FEATURES ....................................................................................................1-2
LIQUID COOLING ENGINE ...................................................................1-2
PARK POSITION ...................................................................................1-2
IMPORTANT INFORMATION .......................................................................1-3

PREPARATION FOR REMOVAL PROCEDURES .................................1-3
REPLACEMENT PARTS ........................................................................1-3
GASKETS, OIL SEALS AND O-RINGS ................................................1-3
LOCK WASHERS/PLATES AND COTTER PINS ..................................1-4
BEARINGS AND OIL SEALS ................................................................1-4
CIRCLIPS ...............................................................................................1-4
CHECKING OF CONNECTIONS ...................................................................1-5
SPECIAL TOOLS ...........................................................................................1-6

GEN
INFO

GEN
MACHINE IDENTIFICATION INFO
GENERAL INFORMATION
MACHINE IDENTIFICATION
VEHICLE IDENTIFICATION NUMBER
The vehicle identification number 1 is
stamped into the left side of the frame.
MODEL LABEL
The model label 1 is affixed to the frame.
This information will be needed to order
spare parts.
1-1

GEN
FEATURES INFO
FEATURES
LIQUID COOLING ENGINE
Compact liquid cooled 45˚ inclined engine.
A liquid cooling system has been incorpo-
rated for stable power and engine endur-
ance.
1 Radiator
2 Thermo switch
3 Fan motor
PARK POSITION
When the drive select lever is shifted into
the park position, a stopper lever is
engaged into the stopper gear preventing
the drive select lever and transmission from
moving.
When the drive select lever is at the “L”,

“H”, “N”, or “R” positions, the stopper
lever end 1 is moved away from the stop-
per gear 2 by the return spring 3.
When the drive select lever is in the “P”
position, the lever cam 4 at the side of the
shift cam 5 lifts the stopper lever end 6
and the stopper lever end locks the drive
axle 7.
When the stopper lever end 1 is not syn-

chronized, a torsion spring 8 retains the
rotation force of the shift cam 5 until it is
synchronized.
1-2

GEN
IMPORTANT INFORMATION INFO
EB101000
IMPORTANT INFORMATION
PREPARATION FOR REMOVAL
PROCEDURES
1.Remove all dirt, mud, dust and foreign
material before removal and disassembly.
2.Use proper tools and cleaning equipment.
Refer to the “SPECIAL TOOLS” section.
3.When disassembling the machine, always
keep mated parts together. This includes
gears, cylinder, piston and other parts that
have been “mated” through normal wear.
Mated parts must always be reused or
replaced as an assembly.
4.During machine disassembly, clean all
parts and place them in trays in the order
of disassembly. This will speed up assem-
bly and allow for the correct installation of
all parts.
5.Keep all parts away from any source of
fire.
EB101010
REPLACEMENT PARTS
1.Use only genuine Yamaha parts for all
replacements. Use oil and grease recom-
mended by Yamaha for all lubrication
jobs. Other brands may be similar in func-
tion and appearance, but inferior in qual-
ity.
EB101020
GASKETS, OIL SEALS AND O-RINGS
1.Replace all gaskets, seals and O-rings
when overhauling the engine. All gasket
surfaces, oil seal lips and O-rings must be
cleaned.
2.Properly oil all mating parts and bearings
during reassembly. Apply grease to the oil
seal lips.
1-3

GEN
IMPORTANT INFORMATION INFO
EB101030
LOCK WASHERS/PLATES AND COTTER
PINS
1.Replace all lock washers/plates 1 and cot-
ter pins after removal. Bend lock tabs
along the bolt or nut flats after the bolt or
nut has been tightened to specification.
EB101040
BEARINGS AND OIL SEALS
1.Install bearings and oil seals so that the
manufacturer’s marks or numbers are vis-
ible. When installing oil seals, apply a
light coating of lightweight lithium base
grease to the seal lips. Oil bearings liber-
ally when installing, if appropriate.
1 Oil seal
CAUTION:
Do not use compressed air to spin the bear-
ings dry. This will damage the bearing sur-
faces.
1 Bearing
EB101050
CIRCLIPS
1.Check all circlips carefully before reas-
sembly. Always replace piston pin clips
after one use. Replace distorted circlips.
When installing a circlip 1, make sure
that the sharp-edged corner 2 is posi-
tioned opposite the thrust 3 it receives.
See sectional view.
4 Shaft
1-4

GEN
CHECKING OF CONNECTIONS INFO
EB801000
CHECKING OF CONNECTIONS
Check the connectors for stains, rust, mois-
ture, etc.
1.Disconnect:
● Connector
2.Check:
● Connector
Moisture → Dry each terminal with an air

blower.
Stains/rust → Connect and disconnect the
terminals several times.
3.Check:
● Connector leads
Looseness → Bend up the pin 1 and con-

nect the terminals.
4.Connect:
● Connector terminals
NOTE:
The two terminals “click” together.
5.Check:
● Continuity (using a pocket tester)
NOTE:
● If there is no continuity, clean the termi-
nals.
● When checking the wire harness be sure
to perform steps 1 to 3.
● As a quick remedy, use a contact revital-
izer available at most part stores.

● Check the connector with a pocket tester
as shown.
1-5

GEN
SPECIAL TOOLS INFO
EB102001
SPECIAL TOOLS
The following special tools are necessary for complete and accurate tune-up and assembly.
Use only the appropriate special tools; this will help prevent damage caused by the use of
inappropriate tools or improvised techniques. Special tools may differ by shape and part
number from country to country. In such a case, two types are provided.
When placing an order, refer to the list provided below to avoid any mistakes.
For US and CDN
P/N. YM-, YU-, YS-, YK-, ACC-
Except for US and CDN
P/N. 90890-
Tool No. Tool name/How to use Illustration

Bolt Slide hammer bolt (M6)/weight/set
90890-01083
Weight
90890-01084
Set These tools are used to remove the
YU-01083-A rocker arm shaft.
Crankcase separating tool
90890-01135
YU-01135-A
This tool is used to separate the crank-
case.
Valve guide remover (7.0 mm)
90890-01225
YM-01225-A
This tool is needed to remove and
install the valve guide.
Valve guide installer (7.0 mm)
90890-04017
YM-04017
This tool is needed to install the valve
guide.
Valve guide reamer (7.0 mm)
90890-01227
YM-01227
This tool is needed to rebore the new
valve guide.
Gear lash measurement tool
90890-01231
YM-01231
This tool is used to measure the gear
lash.
Rotor holding tool
90890-01235 This tool is needed to hold the starter

YU-01235 puller when removing/installing the
starter puller bolt or camshaft sprocket
bolts.
1-6

GEN
SPECIAL TOOLS INFO
Buffer boss installer set
Kit Crankshaft installer bolt
90890-04088
Bolt
90890-01275 These tools are used to install the
crankshaft.
Crankshaft installer set
YU-90050
These tools are used to install the
crankshaft.
Adapter (#11)
Adapter
YM-33279 Spacer (crankshaft installer)
Spacer
90890-04060 These tools are used to install the
YM-90070-A
crankshaft.
Piston pin puller
90890-01304
YU-01304
This tool is used to remove the piston
pin.
Tappet adjusting tool (3 mm)
90890-01311
YU-08035
This tool is necessary for adjusting the
valve clearance.
Fuel level gauge
90890-01312
YM-01312-A
This gauge is used to measure the fuel
level in the float chamber.
Radiator cap tester
90890-01325
YU-24460-01
This tool is used to check the cooling
system.
Adapter
90890-01352
YU-33984
This tool is used to check the cooling
system.
Locknut wrench
90890-01348 This tool is needed when removing or

installing the secondary sheave
spring.
1-7

GEN
SPECIAL TOOLS INFO
Sheave spring compressor
90890-04134
YM-04134 This tool is needed when removing or
spring.
Sheave fixed block
90890-04135
spring.
Flywheel puller
90890-01404
YM-01404
These tools are needed to remove the
rotor.
Damper rod holder (30 mm)
90890-01327
YM-01327 This tool is needed to loosen and
tighten the steering stem bearing
retainer.
Oil filter wrench
90890-01426
YU-38411
This tool is needed to loosen or tighten
the oil filter cartridge.
Ring nut wrench
90890-01430
YM-38404 This tool is needed to removing and
installing the middle driven shaft bear-
ing retainer.
Gear lash measurement tool

90890-01467
YM-01467
90890-01475
YM-01475 This tool is used to measure the gear
lash.
Sheave holder
90890-01701
YU-01880 This tool is needed to hold the primary
sheave when removing or installing
the sheave bolts.
Set Compression gauge set

90890-03081 Adapter
YU-33223
Adapter
90890-04082 These tools are needed to measure
YU-33223-3 engine compression.
1-8

GEN
SPECIAL TOOLS INFO
Pocket tester
90890-03112
YU-03112
This instrument is needed for checking
the electrical system.
Engine tachometer
90890-03113
This tool is needed for observing
engine rpm.
Inductive tachometer
YU-8036-A
This tool is needed for observing
engine rpm.
Timing light
90890-03141
YM-33277-A
This tool is necessary for checking
ignition timing.
Valve spring compressor
90890-04019
YM-04019
This tool is needed to remove and
install the valve assemblies.
Middle driven shaft Middle driven shaft bearing driver
bearing driver
90890-04058 Mechanical seal installer
YM-04058-1
Mechanical seal
installer These tools are used to install the
90890-04078
YM-33221 water pump seal.
Bearing retainer wrench
90890-04050
installing the final drive shaft bearing
retainer.
Universal joint holder
90890-04062
YM-04062
This tool is needed when removing or
installing the universal joint yoke nut.
Clutch holding tool
90890-04086
YM-91042 This tool is needed to hold the clutch
carrier when removing or installing the
carrier nut.
1-9

GEN
SPECIAL TOOLS INFO
Bearing retainer wrench
90890-04128
installing the middle driven pinion
gear bearing retainer.
Pinion gear fix clamp
90890-04129
YM-04129
This tool is used to hold the shift cam.
Ignition checker
90890-06754
This instrument is necessary for check-
ing the ignition system components.
Dynamic spark tester
YM-34487
This instrument is necessary for check-
ing the ignition system components.
Yamaha bond No. 1215

Bond Sealant (Quick Gasket ®)
90890-85505
Sealant
ACC-11001-05-01 This sealant (bond) is used on crank-
case mating surfaces, etc.
1 - 10

SPEC
2
SPEC
CHAPTER 2.
SPECIFICATIONS
GENERAL SPECIFICATIONS.........................................................................2-1
MAINTENANCE SPECIFICATIONS...............................................................2-5
ENGINE ..................................................................................................2-5
CHASSIS ..............................................................................................2-15
ELECTRICAL .........................................................................................2-19
HOW TO USE THE CONVERSION TABLE ................................................2-21
GENERAL TORQUE SPECIFICATIONS ......................................................2-21
LUBRICATION POINTS AND LUBRICANT TYPES ...................................2-22

ENGINE ...............................................................................................2-22
COOLANT FLOW DIAGRAMS ...................................................................2-23
OIL FLOW DIAGRAMS ...............................................................................2-25
CABLE ROUTING ........................................................................................2-28

SPEC

GENERAL SPECIFICATIONS SPEC
SPECIFICATIONS
GENERAL SPECIFICATIONS
Item Standard
Model code: 5GH3 : (For CDN)
5GH4 : (For GB, F, CH)
5GH5 : (For Oceania)
Dimensions:
Overall length 1,965 mm (77.36 in)
Overall width 1,070 mm (42.13 in)
Overall height 1,120 mm (44.09 in)
Seat height 820 mm (32.28 in)
Wheelbase 1,225 mm (48.23 in)
Minimum ground clearance 245 mm (9.65 in)
Minimum turning radius 3,000 mm (118.11 in)
Basic weight:
With oil and full fuel tank 262 kg (578 lb)
Engine:
Engine type Liquid-cooled 4-stroke, SOHC
Cylinder arrangement Forward-inclined single cylinder
Displacement 401 cm3
Bore × stroke 84.5 × 71.5 mm (3.33 × 2.81 in)
Compression ratio 10.5 : 1
Starting system Electric and recoil starter
Lubrication system: Wet sump
Oil type or grade:
Engine oil
0° 10° 30° 50° 70° 90° 110° 130°F
YAMALUBE 4 (20W40) or SAE 20W40

API service SE, SF, SG type or higher
SAE 5W30
-20° -10° 0° 10° 20° 30° 40° 50°C
Final gear oil SAE 80API “GL-4” Hypoid Gear Oil

Differential gear oil SAE 80API “GL-4” Hypoid Gear Oil
Oil capacity:
Engine oil
Periodic oil change 2.3 L (2.0 lmp qt, 2.4 US qt)
With oil filter replacement 2.4 L (2.1 lmp qt, 2.5 US qt)
Total amount 2.6 L (2.3 lmp qt, 2.7 US qt)
Final gear case oil
2-1

Item Standard
Differential gear case oil
Radiator capacity (including all routes) 1.1 L (0.97 lmp qt, 1.16 US qt)
Air filter: Wet type element
Fuel:
Type Regular unleaded gasoline (For CDN, GB, F, CH)
Unleaded fuel only (For Oceania)
Fuel tank capacity 15 L (3.3 lmp gal, 3.9 US gal)
Fuel reserve amount 4.5 L (0.99 lmp gal, 1.19 US gal)
Carburetor:
Type/quantity BSR33/1
Manufacturer MIKUNI
Spark plug:
Type/manufacturer DR8EA/NGK (For CDN, GB, F, CH)
D8EA/NGK (For Oceania)
X24ES-U/DENSO (For Oceania)
Spark plug gap 0.6 ~ 0.7 mm (0.02 ~ 0.03 in)
Clutch type: Wet, centrifugal automatic
Transmission:
Primary reduction system V-belt
Secondary reduction system Spur gear
Secondary reduction ratio 39/24 × 24/18 × 33/9 (7.944)
Transmission type V-belt automatic
Operation Left hand operation
Single speed automatic 2.55 ~ 0.75 : 1
Sub transmission ratio low 45/16 (2.813)
high 38/23 (1.652)
Reverse gear 29/17 (1.706)
Chassis:
Frame type Steel tube frame
Caster angle 4.0˚
Camber angle 1˚
Kingpin angle 11˚
Kingpin offset 1 mm (0.04 in)
Trail 21 mm (0.83 in)
Tread (STD) front 850 mm (33.46 in)
rear 825 mm (32.48 in)
Toe-in 0 ~ 10 mm (0 ~ 0.39 in)
Tire:
Type Tubeless
Size front AT25 × 8–12
rear AT25 × 10–12
2-2

Item Standard
Manufacturer front DUNLOP (For CDN, GB, F, CH)
CHENG SHIN (For Oceania)
rear DUNLOP (For CDN, GB, F, CH)
CHENG SHIN (For Oceania)
Type front KT123 (For CDN, GB, F, CH)
C828 (For Oceania)
rear KT127 (For CDN, GB, F, CH)
C828 (For Oceania)
2-3

Item Standard
Tire pressure (cold tire):
Maximum load* 210 kg (463 lb)
Off-road riding front 22 ~ 28 kPa (0.22 ~ 0.28 kg/cm2, 3.2 ~ 4.0 psi)
rear 22 ~ 28 kPa (0.22 ~ 0.28 kg/cm2, 3.2 ~ 4.0 psi)
*Load in total weight of rider accessories
Brake:
Front brake type Dual disc brake
operation Right hand operation
Rear brake type Single disc brake
operation Left hand and right foot operation
Suspension:
Front suspension Double wishbone
Rear suspension Swingarm (monocross)
Shock absorber:
Front shock absorber Coil spring/oil damper
Rear shock absorber Coil spring/oil damper
Wheel travel:
Front wheel travel 160 mm (6.30 in)
Rear wheel travel 180 mm (7.09 in)
Electrical:
Ignition system C.D.I.
Generator system A.C. magneto
Battery type YTX20L-BS
Battery capacity 12 V 18 AH
Headlight type: Krypton bulb
Bulb wattage × quantity:
Headlight 12 V 30 W/30 W × 2
Tail light 12 V 7.5 W × 1
Meter light 14 V 3.4 W × 1
Indicator lights
Neutral 14 V 1.7 W × 1
Reverse 14 V 1.7 W × 1
Coolant temperature 14 V 1.7 W × 1
Four-wheel drive 14 V 1.7 W × 1
Park 14 V 1.7 W × 1
2-4

MAINTENANCE SPECIFICATIONS SPEC
MAINTENANCE SPECIFICATIONS
ENGINE
Item Standard Limit
Cylinder head:
Warp limit ---- 0.03 mm
(0.0012 in)
Cylinder:
Bore size 84.500 ~ 84.510 mm 84.600 mm
(3.3268 ~ 3.3272 in) (3.3307 in)
Taper limit ---- 0.05 mm
(0.0016 in)
Out of round limit ---- 0.01 mm
(0.0004 in)
Camshaft:
Drive method Chain drive (Left) ----
Cam dimensions
B
Intake “A” 40.62 ~ 40.72 mm 40.52 mm
(1.5992 ~ 1.6031 in) (1.5953 in)
“B” 32.18 ~ 32.28 mm 32.08 mm
(1.2669 ~ 1.2709 in) (1.2630 in)
“C” 8.61 ~ 8.73 mm ----
(0.3390 ~ 0.3437 in)
Exhaust “A” 40.62 ~ 40.72 mm 40.52 mm
(1.5992 ~ 1.6031 in) (1.5953 in)
“B” 32.18 ~ 32.28 mm 32.08 mm
(1.2669 ~ 1.2709 in) (1.2630 in)
“C” 8.61 ~ 8.73 mm ----
(0.3390 ~ 0.3437 in)
Camshaft runout limit ---- 0.03 mm
(0.0012 in)
2-5

Item Standard Limit
Cam chain:
Cam chain type/No. of links 92RH2015/116 ----
Cam chain adjustment method Automatic ----
Rocker arm/rocker arm shaft:
Shaft outside diameter 11.981 ~ 11.991 mm 11.951 mm
(0.4717 ~ 0.4721 in) (0.4705 in)
Arm-to-shaft clearance 0.009 ~ 0.037 mm 0.08 mm
(0.0004 ~ 0.0015 in) (0.0031 in)
Valve, valve seat, valve guide:
Valve clearance (cold) IN 0.06 ~ 0.10 mm ----
(0.0024 ~ 0.0039 in)
EX 0.16 ~ 0.20 mm ----
(0.0063 ~ 0.0079 in)
Valve dimensions
B C
D
A
Head Diameter Face Width Seat Width Margin Thickness
“A” head diameter IN 39.9 ~ 40.1 mm ----

(1.5708 ~ 1.5787 in)
EX 33.9 ~ 34.1 mm ----
(1.3346 ~ 1.3425 in)
“B” face width IN 2.26 mm (0.0890 in) ----
EX 2.26 mm (0.0890 in) ----
“C” seat width IN 1.2 ~ 1.4 mm 1.6 mm
(0.0472 ~ 0.0551 in) (0.0630 in)
EX 1.2 ~ 1.4 mm 1.6 mm
(0.0472 ~ 0.0551 in) (0.0630 in)
“D” margin thickness IN 1.0 ~ 1.4 mm ----
(0.0394 ~ 0.0551 in)
EX 0.8 ~ 1.2 mm ----
(0.0314 ~ 0.0472 in)
Stem outside diameter IN 6.975 ~ 6.990 mm 6.950 mm
(0.2746 ~ 0.2752 in) (0.2736 in)
EX 6.955 ~ 6.970 mm 6.915 mm
(0.2738 ~ 0.2744 in) (0.2722 in)
Guide inside diameter IN 7.000 ~ 7.012 mm 7.030 mm
(0.2756 ~ 0.2761 in) (0.2768 in)
EX 7.000 ~ 7.012 mm 7.030 mm
(0.2756 ~ 0.2761 in) (0.2768 in)
Stem-to-guide clearance IN 0.010 ~ 0.037 mm 0.08 mm
(0.0004 ~ 0.0015 in) (0.0031 in)
EX 0.030 ~ 0.057 mm 0.10 mm
(0.0012 ~ 0.0022 in) (0.0039 in)
2-6

Item Standard Limit
Stem runout limit ---- 0.01 mm
(0.0004 in)
Valve seat width IN 1.2 ~ 1.4 mm ----

(0.0472 ~ 0.0551 in)
EX 1.2 ~ 1.4 mm ----
(0.0472 ~ 0.0551 in)
Valve spring:
Inner spring
Free length IN 39.9 mm (1.57 in) 37.9 mm
(1.49 in)
EX 39.9 mm (1.57 in) 37.9 mm
(1.49 in)
Set length (valve closed) IN 33.6 mm (1.32 in) ----
EX 33.6 mm (1.32 in) ----
Compressed pressure
(installed) IN 104.9 ~ 120.6 N (10.70 ~ ----
12.30 kg, 23.58 ~ 27.11 lb)
EX 104.9 ~ 120.6 N (10.70 ~ ----
12.30 kg, 23.58 ~ 27.11 lb)
Tilt limit IN 2.5˚/1.6 mm
* (2.5˚/0.06 in)
EX 2.5˚/1.6 mm
(2.5˚/0.06 in)
Direction of winding
(top view) IN Counterclockwise ----
EX Counterclockwise ----
Outer spring
Free length IN 43.27 mm (1.70 in) 41.27 mm
(1.62 in)
EX 43.27 mm (1.70 in) 41.27 mm
(1.62 in)
Set length (valve closed) IN 36.6 mm (1.44 in) ----
EX 36.6 mm (1.44 in) ----
2-7

Item Standard Limit
Compressed pressure
(installed) IN 235.4 ~ 251.1 N (24.00 ~ ----
25.60 kg, 52.92 ~ 56.45 lb)
EX 235.4 ~ 251.1 N (24.00 ~ ----
25.60 kg, 52.92 ~ 56.45 lb)
Tilt limit IN 2.5˚/1.6 mm
* (2.5˚/0.06 in)
EX 2.5˚/1.6 mm
(2.5˚/0.06 in)
Direction of winding
(top view) IN Clockwise ----
EX Clockwise ----
Piston:
Piston to cylinder clearance 0.040 ~ 0.065 mm 0.15 mm
(0.0016 ~ 0.0026 in) (0.0059 in)
Piston size “D” 84.445 ~ 84.460 mm ----
(3.3246 ~ 3.3252 in)
H
D
Measuring point “H” 5 mm (0.20 in) ----

Piston off-set 0.5 mm (0.0200 in) ----
Piston pin bore inside diameter 20.004 ~ 20.015 mm 20.045 mm
(0.7876 ~ 0.7880 in) (0.7892 in)
Piston pin outside diameter 19.993 ~ 20.000 mm 19.973 mm
(0.7871 ~ 0.7874 in) (0.7863 in)
Piston rings:
Top ring
B
T
Type Barrel ----

Dimensions (B × T) 1.2 × 3.1 mm ----
(0.0472 × 0.1220 in)
End gap (installed) 0.2 ~ 0.4 mm 0.65 mm
(0.0079 ~ 0.0157 in) (0.0256 in)
Side clearance (installed) 0.03 ~ 0.08 mm 0.13 mm
(0.0012 ~ 0.0031 in) (0.0051 in)
2-8

Item Standard Limit
2nd ring
B
T
Type Taper ----

Dimensions (B × T) 1.2 × 3.6 mm ----
(0.0472 × 0.1417 in)
End gap (installed) 0.4 ~ 0.6 mm 0.95 mm
(0.0157 ~ 0.0236 in) (0.0374 in)
Side clearance 0.03 ~ 0.07 mm 0.13 mm
(0.0012 ~ 0.0028 in) (0.0051 in)
Oil ring
B
T
Dimensions (B × T) 2.8 × 2.8 mm ----

(0.1102 × 0.1102 in)
End gap (installed) 0.2 ~ 0.7 mm ----
(0.0079 ~ 0.0276 in)
Crankshaft:
D
C1 C2
B
A
Crank width “A” 62.95 ~ 63.00 mm ----
(2.4783 ~ 2.4803 in)
Runout limit C1 ---- 0.03 mm
(0.0012 in)
C2 ---- 0.03 mm
(0.0012 in)
Big end side clearance “D” 0.25 ~ 0.75 mm 1.0 mm
(0.0098 ~ 0.0295 in) (0.0394 in)
Big end radial clearance “E” 0.010 ~ 0.025 mm ----
(0.0004 ~ 0.0010 in)
Balancer:
Balancer drive method Gear ----
Automatic centrifugal clutch:
Clutch shoe thickness 1.5 mm (0.06 in) 1.0 mm
(0.04 in)
Clutch-in revolution 1,900 ~ 2,300 r/min ----
Clutch-stall revolution 3,300 ~ 3,900 r/min ----
2-9

Item Standard Limit
Transmission:
Main axle deflection limit ---- 0.06 mm
(0.0024 in)
Drive axle deflection limit ---- 0.06 mm
(0.0024 in)
Shifter:
Shifter type Cam drum and guide bar ----
Air filter oil grade: Engine oil ----
Carburetor:
I. D. mark 5GH1 00 (For CDN) ----
5GH4 20 (For GB, F, CH, Oceania)
Main jet (M.J) #132.5 ----
Main air jet (M.A.J) #50 ----
Jet needle (J.N) 5EP7-55-3 ----
Needle jet (N.J) P-0M ----
Pilot air jet (P.A.J.1) #80 ----
Pilot air jet (P.A.J.2) 1.3 ----
Pilot outlet (P.O) 0.95 ----
Pilot jet (P.J) #17.5 ----
Bypass 1 (B.P.1) 0.8 ----
Bypass 2 (B.P.2) 0.8 ----
Bypass 3 (B.P.3) 0.8 ----
Pilot screw (P.S.) 2-1/2
Valve seat size (V.S) 2.0 ----
Starter jet (G.S.1) #70 ----
Starter jet (G.S.2) 0.9
Throttle valve size (Th.V) #90 ----
Float height (F.H) 13 mm (0.51 in) ----
Fuel level (F.L) 2 ~ 3 mm (0.08 ~ 0.12 in) ----
Engine idle speed 1,450 ~ 1,550 r/min ----
Intake vacuum 32 kPa (240 mmHg, 9.45 inHg) ----
Oil pump:
Oil pump type Trochoid ----
Tip clearance “A” or “B” 0.15 mm (0.006 in) 0.2 mm
(0.008 in)
Side clearance 0.04 ~ 0.09 mm ----
(0.002 ~ 0.004 in)
Bypass valve setting pressure 78 ~ 118 kPa (0.78 ~ 1.18 kg/cm2, ----
11.3 ~ 17.11 psi)
Oil pressure (hot) 7 kPa (0.07 kg/cm2, 1.02 psi) at ----
1,500 r/min
Pressure check location Cylinder head ----
Cooling system:
Radiator core
Width 300 mm (11.8 in) ----
Height 219 mm (8.62 in) ----
Thickness 16 mm (0.63 in) ----
2 - 10

Item Standard Limit
Radiator cap opening pressure 93.3 ~ 122.7 kPa (0.933 ~ ----
1.227 kg/cm2, 13.53 ~ 17.79 psi)
Radiator capacity 0.55 L (0.48 Imp qt, 0.58 US qt) ----
Coolant reservoir
Capacity 0.25 L (0.22 Imp qt, 0.26 US qt) ----
From low to full level 0.15 L (0.13 Imp qt, 0.16 US qt) ----
Water pump:
Type Single suction centrifugal pump ----
Reduction ratio 38/32 (1.188)
Thermostat:
Valve opening temperature 63.5 ~ 66.5 °C (146.3 ~ 151.7 °F) ----
Valve full open temperature 80 °C (176 °F) ----
Valve lift-full open 3 mm (0.12 in) ----
Shaft drive:
Middle gear backlash 0.1 ~ 0.3 mm (0.004 ~ 0.012 in) ----
Final gear backlash 0.1 ~ 0.2 mm (0.004 ~ 0.008 in) ----
Differential gear backlash 0.08 ~ 0.39 mm ----
(0.003 ~ 0.015 in)
Lubrication chart:
2 - 11

Item Standard Limit
Cylinder head tightening sequence:
2 - 12

Tightening torques
Part Thread Tightening torque

Part to be tightened Q’ty Remarks
name size Nm m·kg ft·lb
Cylinder head oil passage Union bolt M6 1 7 0.7 5.1
Cylinder head (exhaust pipe) Stud bolt M8 2 15 1.5 11
Cylinder head Bolt M10 4 40 4.0 29
Bolt M6 2 10 1.0 7.2
Camshaft sprocket cover baffle
Bolt M6 2 10 1.0 7.2 LT
plate
Camshaft bearing retainer Bolt M6 2 8 0.8 5.8
Spark plug — M12 1 18 1.8 13
Cylinder drain screw Screw M6 1 10 1.0 7.2
Starter clutch Bolt M10 1 50 5.0 36
Camshaft sprocket Bolt M10 1 60 6.0 43
Timing chain tensioner cap Bolt M11 1 23 2.3 17
Timing chain tensioner Bolt M6 2 11 1.1 8.0
Timing chain guide (intake) Bolt M6 2 10 1.0 7.2 LT
Valve adjusting screw Nut M7 2 20 2.0 14

Radiator Bolt M6 2 7 0.7 5.1
Oil pump assembly Screw M6 3 8 0.8 5.8
Oil pump Screw M6 1 8 0.8 5.8
Oil strainer cover Plug M35 1 32 3.2 23
Oil drain plug Bolt M14 1 23 2.3 17
Oil pump drive gear Nut M14 1 50 5.0 36
Oil delivery pipe Union bolt M8 2 18 1.8 13
Oil filter bolt Union bolt M20 1 63 6.3 46 E
Oil filter cartridge — M20 1 17 1.7 12

Carburetor joint Bolt M8 2 20 2.0 14
Muffler and exhaust pipe Bolt M8 2 15 1.5 11
Muffler and pipe Bolt M6 1 8 0.8 5.8
Muffler protector 1, 2 Bolt M6 7 14 1.4 10 LT
Exhaust pipe protector Bolt M6 3 14 1.4 10 LT
Exhaust pipe Nut M8 2 20 2.0 14

Muffler Bolt M10 2 25 2.5 18
Exhaust pipe stay Bolt M6 4 14 1.4 10
Exhaust pipe protector stay Bolt M6 1 11 1.1 8.0
Crankcase cover Screw M6 4 8 0.8 5.8 LT
Oil seal retainer Screw M5 3 7 0.7 5.1 LT
Drive belt case cover Bolt M6 12 10 1.0 7.2

Crankcase oil passage plug Plug M18 1 55 5.5 40
Bearing retainer (right crankcase) Screw M6 1 11 1.1 8.0 LT
Air duct (front) Bolt M6 1 4 0.4 2.9

Air duct (rear) Bolt M6 2 5 0.5 3.6
Plug (right crankcase) Bolt M8 1 15 1.5 11
Bearing retainer (left crankcase) Bolt M6 2 10 1.0 7.2 LT
2 - 13

Part Thread Tightening torque
Part to be tightened Q’ty Remarks
name size Nm m·kg ft·lb
Crankcase cover (left) Bolt M6 6 10 1.0 7.2 LT
Recoil starter Bolt M6 4 10 1.0 7.2 LT
Starter one-way clutch Bolt M8 6 30 3.0 22 LT
Clutch carrier assembly Nut M22 1 140 14 100 Stake

Middle drive shaft bearing Torx
M8 4 25 2.5 18 LT
retainer screw
Middle driven shaft drive pinion
Nut M22 1 130 13 94 Stake
gear
Middle drive shaft bearing housing Bolt M8 6 32 3.2 23
Middle driven gear bearing LT
Nut M65 1 110 11 80

retainer Left-hand threads
Yoke (middle driven gear) Nut M14 1 97 9.7 70 LT
Middle driven gear bearing hous-

Bolt M8 4 25 2.5 18
ing
Middle driven shaft bearing LT
Nut M55 1 80 8.0 58

retainer Left-hand threads
Shift arm Bolt M6 1 14 1.4 10
Shift rod Nut M8 2 15 1.5 11
Primary sheave assembly Nut M16 1 100 10.0 72
Secondary sheave assembly Nut M16 1 100 10.0 72
Secondary sheave spring retainer Nut M36 1 90 9.0 65
Shift lever Bolt M6 1 14 1.4 10
Shift control cable — M12 1 6 0.6 4.3
Select lever unit Bolt M8 3 15 1.5 11
Shift cam ball holding bolt — M14 1 18 1.8 13
CDI unit Screw M6 2 7 0.7 5.1
Neutral switch — M10 1 20 2.0 14
Reverse switch — M10 1 20 2.0 14
Parking switch — M10 1 20 2.0 14
Stator assembly Screw M6 3 7 0.7 5.1 LT
Pickup coil Bolt M5 2 7 0.7 5.1 LT
Ignition coil Bolt M6 2 7 0.7 5.1

Thermo switch (cylinder head) — M1/8 1 8 0.8 5.8
Speed sensor Bolt M6 1 10 1.0 7.2 LT
Thermo switch (radiator) — M18 1 28 2.8 20

Speedometer gear unit Bolt M6 2 10 1.0 7.2 LT
2 - 14

CHASSIS
Item Standard Limit
Steering system:
Steering bearing type Bushings (top) ----
Ball bearing (bottom)
Front suspension:
Shock absorber travel 106 mm (4.17 in) ----
Fork spring free length 317.5 mm (12.50 in) ----
Spring fitting length 256.5 mm (10.09 in) ----
Spring rate (K1) 14 N/mm (1.43 kg/mm, 79.94 lb/in) ----
Stroke (K1) 0 ~ 106 mm (0 ~ 4.17 in) ----
Optional spring No ----
Rear suspension:
Shock absorber travel 130 mm (5.12 in) ----
Spring free length 319 mm (12.56 in) ----
Spring fitting length 285.5 mm (11.24 in) ----
Spring rate (K1) 31.4 N/mm ----
(3.20 kg/mm, 179.29 lb/in)
Stroke (K1) 0 ~ 130 mm (0 ~ 5.12 in) ----
Optional spring No ----
Swingarm:
Free play limit end ---- 1 mm
(0.04 in)
side ---- 1 mm
(0.04 in)
Front wheel:
Type Panel wheel ----
Rim size 12 × 6.0 AT ----
Rim material Steel ----
Rim runout limit radial ---- 2 mm
(0.08 in)
lateral ---- 2 mm
(0.08 in)
Rear wheel:
Type Panel wheel ----
Rim size 12 × 7.5 AT ----
Rim material Steel ----
Rim runout limit radial ---- 2 mm
(0.08 in)
lateral ---- 2 mm
(0.08 in)
2 - 15

Item Standard Limit
Front disc brake:
Type Dual ----
Disc outside diameter × thickness 180.0 × 3.5 mm (7.09 ~ 0.14 in) ----
Pad thickness inner 4.5 mm (0.18 in) 1 mm
(0.04 in)
Pad thickness outer 4.5 mm (0.18 in) 1 mm
(0.04 in)
Master cylinder inside diameter 14 mm (0.55 in) ----
Caliper cylinder inside diameter 32 mm (1.26 in) ----
Brake fluid type DOT 4 ----
Rear disc brake:
Type Single ----
Disc outside diameter × thickness 220.0 × 3.6 mm (8.66 ~ 0.14 in) ----
Pad thickness inner 5.6 mm (0.22 in) 1 mm
(0.04 in)
Pad thickness outer 5.6 mm (0.22 in) 1 mm
(0.04 in)
Master cylinder inside diameter 14 mm (0.55 in) ----
Caliper cylinder inside diameter 32 mm (1.26 in) ----
Brake fluid type DOT 4 ----
Brake lever and brake pedal:
Brake lever free play (at lever end) 0 mm (0 in) ----
Brake lever free play (left) 0.5 ~ 2 mm (0.02 ~ 0.08 in) ----
Brake pedal position 53 ~ 60 mm (2.09 ~ 2.36 in) ----
Throttle lever free play 3 ~ 5 mm (0.12 ~ 0.20 in) ----
2 - 16

Tightening torques
Tightening torque
Part to be tightened Thread size Remarks
Nm m·kg ft·lb
Engine bracket (front-upper) and frame M8 33 3.3 24
Engine bracket (front-lower) and frame M8 33 3.3 24
Engine bracket (front-upper) and engine M10 42 4.2 30
Engine bracket (front-lower) and engine M10 42 4.2 30
Engine and frame M10 56 5.6 40
Frame and bearing retainer (steering stem
M42 40 4.0 29
holder bearing)
Select lever assembly and frame M8 23 2.3 17
Pivot shaft and frame M12 82 8.2 60
Rear shock absorber and frame M12 82 8.2 60
Final gear case and swingarm M10 57 5.7 41 LT
Final gear case and swingarm M10 63 6.3 46

Differential gear case and frame M10 55 5.5 40
Front arm and frame M10 45 4.5 32 LS
Front shock absorber and frame M10 45 4.5 32

Front shock absorber and upper front arm M10 45 4.5 32
Steering stem, pitman arm and frame M14 110 11.0 80 LS
Use lock
Steering stem holder and frame M8 23 2.3 17
washer
Steering stem and handlebar holder M8 20 2.0 14
Pitman arm and tie-rod end M10 25 2.5 18
Tie-rod and locknut M10 15 1.5 11
Steering knuckle and upper front arm M10 25 2.5 18
Steering knuckle and lower front arm M10 48 4.8 35 LS
Steering knuckle and tie-rod M10 25 2.5 18

Fuel tank and fuel cock M6 4 0.4 2.9
Front wheel and wheel hub M10 55 5.5 40
Front axle and wheel hub M16 150 15.0 110
Steering knuckle and brake caliper M8 30 3.0 22
Front brake disc and wheel hub M8 30 3.0 22 LT
Rear wheel and rear wheel hub M10 55 5.5 40

Rear axle and nut M16 150 15 110
Swingarm and rear brake caliper M8 30 3.0 22
Rear brake disc and brake disc bracket M8 28 2.8 20 LT
Front brake pipe nut M10 19 1.9 13

Front brake hose union bolt M10 27 2.7 19
Rear brake hose union bolt M10 30 3.0 22
Bleed screw M8 6 0.6 4.3
Master cylinder and handlebar M6 7 0.7 5.1
Footrest and frame M8 33 3.3 24
2 - 17

Tightening torque
Part to be tightened Thread size Remarks
Nm m·kg ft·lb
Front bumper and frame M8 33 3.3 24
Front carrier and frame M8 33 3.3 24
Front carrier and front bumper M8 33 3.3 24
Rear carrier and frame M8 33 3.3 24
Differential gear case filler bolt M14 23 2.3 16
Differential gear case drain bolt M10 10 1.0 7
Ring gear M8 39 3.9 28 LT
Differential gear case and bearing housing M8 25 2.5 18

Gear motor M8 13 1.3 9.4
Four-wheel drive switch M10 20 2.0 14
Final gear case oil filler bolt M14 23 2.3 16
Final gear case oil drain bolt M14 23 2.3 16
Bearing retainer (drive pinion gear) M65 100 10.0 72
Final gear case and bearing housing M10 40 4.0 29
Final gear case and bearing housing M8 23 2.3 17
2 - 18

ELECTRICAL
Item Standard Limit
Voltage: 12 V ----
Ignition system:
Ignition timing (B.T.D.C.) 10˚/ 1,000 r/min ----
Advanced timing (B.T.D.C.) 33˚/ 5,000 r/min ----
Advancer type Digital type ----
C.D.I.:
Magneto model/manufacturer F4T46471/MITSUBISHI ----
Pickup coil resistance/color 459 ~ 561 Ω at 20 ˚C (68 ˚F)/ ----
White/Red – White/Green
Rotor ratation direction sensing coil resis- 0.104 ~ 0.127 Ω at 20 ˚C (68 ˚F)/ ----
tance/color Red – White/Blue
C.D.I. unit model/manufacturer F8T36472/MITSUBISHI ----
Ignition coil:
Model/manufacturer 2JN/YAMAHA ----
Minimum spark gap 6 mm (0.24 in) ----
Primary winding resistance 0.18 ~ 0.28 Ω at 20 ˚C (68 ˚F) ----
Secondary winding resistance 6.32 ~ 9.48 kΩ at 20 ˚C (68 ˚F) ----
Spark plug cap:
Type Resin type ----
Resistance 10 kΩ ----
Charging system:
Type A.C. magneto generator ----
Model/manufacturer F4T464/MITSUBISHI ----
Nominal output 14 V 12 A at 3,000 r/min ----
Charging coil resistance/color 0.70 ~ 0.86 Ω at 20 ˚C (68 ˚F)/ ----
White – White
Rectifier:
Model/manufacturer SH640E-11/SHINDENGEN ----
Capacity 14 A ----
Withstand voltage 200 V ----
Electric starter system:
Type Constantmesh type ----
Starter motor
Model/manufacturer SM-13/MITSUBA ----
I.D. number SM-13486 ----
Output 0.7 kW ----
Armature coil resistance 0.025 ~ 0.035 Ω at 20 ˚C (68 ˚F) ----
Brush overall length 10 mm (0.39 in) 5 mm
(0.20 in)
Spring force 7.65 ~ 10.01 N (27.54 ~ 36.03 oz) ----
Commutator diameter 28 mm (1.10 in) 27 mm
(1.06 in)
Mica undercut 0.7 mm (0.03 in) ----
2 - 19

Item Standard Limit
Starter relay
Model/manufacturer MS5F-561/JIDECO ----
Amperage rating 180 A ----
Coil winding resistance 4.18 ~ 4.62 Ω at 20 ˚C (68 ˚F) ----
Horn:
Type Plane type ----
Quantity 1 ----
Model/manufacturer MF-12/NIKKO ----
Maximum amperage 1.5 A ----
Performance 100 ~ 108 db/2 m ----
Coil winding resistance 4.35 ~ 4.80 Ω ----
Electric fan:
Running rpm 3,000 r/min ----
Thermostat switch:
Model/manufacturer 4BA/DENSO ----
Circuit breaker:
Type Fuse ----
Amperage for individual circuit
Main fuse 30 A × 1 ----
Headlight fuse 15 A × 1 ----
Signal fuse 10 A × 1 ----
Ignition fuse 10 A × 1 ----
Auxiliary DC jack fuse 10 A × 1 ----
Four-wheel drive fuse 3A×1 ----
Reserve 30 A × 1 ----
Reserve 15 A × 1 ----
Reserve 10 A × 1 ----
Reserve 3A×1 ----
2 - 20

HOW TO USE THE CONVERSION TABLE/
GENERAL TORQUE SPECIFICATIONS SPEC
EB201000 EB202001
HOW TO USE THE CONVERSION GENERAL TORQUE

TABLE SPECIFICATIONS
All specification data in this manual are This chart specifies torque for standard fas-
listed in SI and METRIC UNITS. teners with standard I.S.O. pitch threads.
Use this table to convert METRIC unit data Torque specifications for special compo-
to IMPERIAL unit data. nents or assemblies are provided for each
chapter of this manual. To avoid warpage,
Ex.
tighten multi-fastener assemblies in a criss-
METRIC MULTIPLIER IMPERIAL cross fashion, in progressive stages, until
** mm × 0.03937 = ** in the specified torque is reached. Unless oth-
2 mm × 0.03937 = 0.08 in erwise specified, torque specifications
require clean, dry threads. Components
CONVERSION TABLE
should be at room temperature.
METRIC TO IMPERIAL
Metric unit Multiplier Imperial unit
m·kg 7.233 ft·lb
m·kg 86.794 in·lb
Torque
cm·kg 0.0723 ft·lb
cm·kg 0.8679 in·lb
kg 2.205 lb
Weight
g 0.03527 oz
Speed km/hr 0.6214 mph
km 0.6214 mi
m 3.281 ft
Distance m 1.094 yd A: Distance between flats
cm 0.3937 in B: Outside thread diameter
mm 0.03937 in
cc (cm3) 0.03527 oz (IMP liq.) General torque
Volume/ cc (cm3) 0.06102 cu·in A B specifications
Capacity lt (liter) 0.8799 qt (IMP liq.) (nut) (bolt)
lt (liter) 0.2199 gal (IMP liq.) Nm m•kg ft•lb
kg/mm
55.997 lb/in
10 mm 6 mm 6 0.6 4.3
kg/cm2
Misc. 14.2234 psi (lb/in2) 12 mm 8 mm 15 1.5 11
Centigrade
9/5+32 Fahrenheit (˚F)
(˚C)
14 mm 10 mm 30 3.0 22
17 mm 12 mm 55 5.5 40
19 mm 14 mm 85 8.5 61
22 mm 16 mm 130 13.0 94
2 - 21

LUBRICATION POINTS AND LUBRICANT TYPES SPEC
LUBRICATION POINTS AND LUBRICANT TYPES
ENGINE
Lubrication points Lubricant type
Oil seal lips (all) LS
O-ring (all) LS
Bearings (all) E
Crank pin E
Connecting rod (bearing) E
Camshaft sprocket M
Crankshaft E
Piston surface/piston rings E
Piston pin E
Baffer boss E
Valve stem/valve stem end M
Rocker arm shaft E
Rocker arm M
Camshaft lobe/journal M
Cylinder head bolt E
Oil pump shaft, rotor, housing E
Oil filter O-ring E
Starter idle gear shaft E
Transmission gear (wheel/pinion) M
Axle (main/drive) M
Shift fork/guide bar E
Shift cam/shift shaft/shift cam stopper ball E
Shift lever (select lever)/shift guide LS
Shift cam lever M
Stopper lever E
Clutch housing E
One-way bearing M
Drive chain/sprocket E
Driven cam M
Front drive shaft collar E
Crankcase mating surfaces Sealant (Quick Gasket®)

Yamaha Bond No.1215
Stater lead grommet Sealant (Quick Gasket®)
(left side crankcase) Yamaha Bond No.1215
2 - 22

COOLANT FLOW DIAGRAMS SPEC
COOLANT FLOW DIAGRAMS
1 Radiator
2 Thermo switch
3 Fan motor
2 - 23

COOLANT FLOW DIAGRAMS SPEC
1 Radiator
2 Thermostat
2 - 24

OIL FLOW DIAGRAMS SPEC
OIL FLOW DIAGRAMS
1 Camshaft
2 Crankshaft
3 Drive axle
2 - 25

1 Oil filter
2 - 26

1 Oil pump
2 Oil strainer
2 - 27

CABLE ROUTING SPEC
CABLE ROUTING
1 Rear brake switch 0 Coolant reservoir breather hose
2 Rear brake cable A Sub-wire harness 1 (to fan motor coupler)
3 Front brake hose B Sub-wire harness 1 (to gear motor and four-
4 On command four-wheel drive switch wheel drive switch)
5 Throttle cable C Differential gear case breather hose
6 On command four-wheel drive switch lead D Fan motor breather hose
7 Front brake switch lead E Horn switch
8 Handlebar switch
9 Starter cable
2 - 28

CABLE ROUTING SPEC
1 Headlight coupler A Differential gear case breather hose
2 Terminal B Indicator light coupler
3 Terminal coupler C Main switch coupler
4 Engine temperature warning light D Ignition coil lead
5 Four-wheel drive indicator light E Ignition coil
6 Neutral indicator light F Circuit braker
7 Parking indicator light
8 Reverse indicator light Å Connect the headlight lead of the circuit
9 Coolant reservoir breather hose breaker to the headlight on the right side.
0 Fan motor breather hose
2 - 29

CABLE ROUTING SPEC
1 Thermo switch 0 Speed sensor
2 Fuel tank breather hose A CDI magneto lead
3 Starter motor lead B Final drive gear case breather hose
4 Negative battery lead C Rectifier/regulator
5 Speed sensor D Sub-wire harness 1
6 Carburetor drain hose E Coolant reservoir breather hose
7 Wire harness F Coolant reservoir hose
8 Sub-wire harness 2 G Speedometer cable
9 Ground lead
2 - 30

CABLE ROUTING SPEC
Å To hole on the front fender.
ı Insert the fuel tank into the hole in the handlebar cover.
Ç Fasten the CDI magneto lead and starter motor lead with a plastic band.
Î To hole on the rear fender.
‰ Pass the speedometer cable through the guide on the air duct.
2 - 31

CABLE ROUTING SPEC
1 Cylinder head breather hose
2 Spark plug lead
3 Rear brake cable
4 Select lever control cable
5 Rear brake reservoir hose
6 Rear brake hose
2 - 32

CABLE ROUTING SPEC
1 Diode 1 A Negative battery lead
2 Diode 2 B Final drive gear case breather hose
3 Positive battery lead C Cylinder head breather hose
4 Taillight lead D Starter cable
5 Starter relay E Rear brake cable
6 CDI unit F Wire harness
7 Main fuse G Rear brake hose
8 Reverse relay
9 Starting circuit cut-off relay Å 65 ~ 75 mm (2.6 ~ 3.0 in)
0 Fuse box
2 - 33

SPEC
2 - 34

INSP
ADJ 3
INSP
ADJ
CHAPTER 3.
PERIODIC INSPECTIONS AND ADJUSTMENTS
INTRODUCTION ...........................................................................................3-1
PERIODIC MAINTENANCE/LUBRICATION INTERVALS ...........................3-1
SEAT, CARRIERS, FENDERS AND FUEL TANK .........................................3-3

SEAT AND SIDE PANELS ....................................................................3-3
FRONT CARRIER, FRONT BUMPER AND FRONT FENDER ...............3-4
REAR CARRIER AND REAR FENDER ..................................................3-6
FUEL TANK ...........................................................................................3-8
FOOTREST BOARDS ....................................................................................3-9
ENGINE .......................................................................................................3-10
VALVE CLEARANCE ADJUSTMENT .................................................3-10
TIMING CHAIN ADJUSTMENT .........................................................3-13
IDLING SPEED ADJUSTMENT ..........................................................3-13
THROTTLE LEVER FREE PLAY ADJUSTMENT ................................3-14
SPEED LIMITER ADJUSTMENT ........................................................3-16
STARTER LEVER FREE PLAY ADJUSTMENT ..................................3-17
SPARK PLUG INSPECTION ................................................................3-18
IGNITION TIMING CHECK ..................................................................3-19
COMPRESSION PRESSURE MEASUREMENT .................................3-20
ENGINE OIL LEVEL INSPECTION ......................................................3-22
ENGINE OIL REPLACEMENT .............................................................3-23
AIR FILTER CLEANING .......................................................................3-26
COOLANT LEVEL INSPECTION .........................................................3-28
COOLANT REPLACEMENT ................................................................3-29
COOLANT TEMPERATURE INDICATOR LIGHT CHECK ..................3-33
V-BELT INSPECTION ..........................................................................3-33
CHASSIS .....................................................................................................3-35
FRONT BRAKE ADJUSTMENT ..........................................................3-35
REAR BRAKE ADJUSTMENT ............................................................3-35
BRAKE FLUID LEVEL INSPECTION ...................................................3-38
FRONT BRAKE PAD INSPECTION .....................................................3-39
REAR BRAKE PAD INSPECTION .......................................................3-39
BRAKE HOSE INSPECTION ...............................................................3-39
AIR BLEEDING (HYDRAULIC BRAKE SYSTEM) ...............................3-40
SELECT LEVER CONTROL CABLE AND
SHIFT ROD ADJUSTMENT ............................................................3-42
FINAL GEAR OIL LEVEL INSPECTION ..............................................3-43
FINAL GEAR REPLACEMENT ............................................................3-44
DIFFERENTIAL GEAR OIL INSPECTION ............................................3-45

INSP
ADJ
DIFFERENTIAL GEAR OIL REPLACEMENT .......................................3-45
CONSTANT VELOCITY JOINT DUST BOOT INSPECTION ..............3-46
STEERING SYSTEM INSPECTION ....................................................3-46
TOE-IN ADJUSTMENT .......................................................................3-47
FRONT SHOCK ABSORBER ADJUSTMENT .....................................3-49
REAR SHOCK ABSORBER ADJUSTMENT .......................................3-49
TIRE INSPECTION ...............................................................................3-49
WHEEL INSPECTION ..........................................................................3-52
CABLE INSPECTION AND LUBRICATION ........................................3-52
LEVERS, PEDAL, ETC. LUBRICATION ...............................................3-53
ELECTRICAL ................................................................................................3-54
BATTERY INSPECTION ......................................................................3-54
FUSE INSPECTION .............................................................................3-59
HEADLIGHT BEAM ADJUSTMENT ...................................................3-61
HEADLIGHT BULB REPLACEMENT ..................................................3-61

INTRODUCTION/PERIODIC MAINTENANCE/ INSP
LUBRICATION INTERVALS ADJ
EB300000
PERIODIC INSPECTIONS AND ADJUSTMENTS

INTRODUCTION
This chapter includes all information necessary to perform recommended inspections and
adjustments. These preventive maintenance procedures, if followed, will ensure more reli-
able vehicle operation and a longer service life. The need for costly overhaul work will be
greatly reduced. This information applies to vehicles already in service as well as to new vehi-
cles that are being prepared for sale. All service technicians should be familiar with this entire
chapter.
EB301000
PERIODIC MAINTENANCE/LUBRICATION INTERVALS

INITIAL EVERY
ITEM ROUTINE 1 3 6 6 1
month months months months year
• Check valve clearance.
Valves*
• Adjust if necessary.
• Check coolant leakage.
Cooling system • Repair if necessary.
• Replace coolant every 24 months.
• Check condition.
Spark plug • Adjust gap and clean.
• Replace if necessary.
• Clean. Every 20~40 hours
Air filter
• Replace if necessary. (More often in wet or dusty areas.)
• Check and adjust idle speed/starter operation.
Carburetor*
• Adjust if necessary.
• Check fuel hose for cracks or damage.
Fuel line*
• Replace if necessary.
Engine oil • Replace (warm engine before draining).
Engine oil filter • Replace.
Engine oil strainer* • Clean.
Final gear oil • Check oil level/oil leakage.
Differential gear oil • Replace every 12 months.
• Check operation/fluid leakage.
Front brake*
• Correct if necessary.
• Check operation/fluid leakage.
Rear brake*
• Correct if necessary.
• Check operation.
V-belt* • Check for cracks or damage every 12 months or
2.400 km (1.500 mi), whichever comes first.
• Check balance/damage/runout.
Wheels*
• Repair if necessary.
• Check bearing assemblies for looseness/damage.
Wheel bearing*
• Replace if damaged.
Front and rear • Check operation.
suspension* • Correct if necessary.
• Check operation/replace if damaged.
Steering system*
• Check toe-in/adjust if necessary.
• Check operation.
Front axle boots*
• Replace if damaged.
Fittings and fasten- • Check all chassis fittings and fasteners.
ers* • Correct if necessary.
* It is recommended that these items be serviced by a Yamaha dealer.
3-1

INSP
PERIODIC MAINTENANCE/LUBRICATION INTERVALS ADJ
NOTE:
● Recommended brake fluid: DOT 4
● Brake fluid replacement:
1.When disassembling the master cylinder or caliper cylinder, replace the brake fluid. Nor-
mally check the brake fluid level and add fluid as required.
2.On the inner parts of the master cylinder and caliper cylinder, replace the oil seals every
two years.
3.Replace the brake hoses every four years, or if cracked or damaged.
WARNING
Indicates a potential hazard that could result in serious injury or death.
3-2

INSP
SEAT, CARRIERS, FENDERS AND FUEL TANK ADJ
SEAT, CARRIERS, FENDERS AND FUEL TANK
SEAT AND SIDE PANELS
Order Job name/Part name Q’ty Remarks

Seat and side panels removal Remove the parts in the order below.
1 Seat 1 NOTE:
Pull up the seat lock lever, then pull up
on the rear of the seat.
2 Fuel tank side panel (left) 1
3 Fuel tank side panel (right) 1
4 Engine side panel 1
5 Engine side cover 1
For installation, reverse the removal
procedure.
3-3

INSP
FRONT CARRIER, FRONT BUMPER AND FRONT FENDER

Front carrier, front bumper and front Remove the parts in the order below.
fender removal
Seat and fuel tank side panels Refer to “SEAT AND SIDE PANELS”.
1 Front carrier 1
2 Front fender panel 1
3 Engine skid plate (front) 1
4 Front bumper 1
5 Headlight coupler 2
6 Front grill 1
7 Handlebar cover 1
8 Fuel tank cover 1
3-4

INSP

9 Indicator light coupler 2 Disconnect.
10 Sub-wire harness 1 coupler 1 Disconnect.
11 Main switch coupler 1 Disconnect.
12 Auxiliary DC jack coupler 1 Disconnect.
13 Speedometer light coupler 1 Disconnect.
14 Speedometer cable 1 Disconnect.
15 Coolant reservoir breather hose 1
16 Fan motor breather hose 1
17 Differential gear case breather hose 1
18 Front fender 1
19 Drain hose 1
procedure.
3-5

INSP
REAR CARRIER AND REAR FENDER

p

Rear carrier and rear fender removal Remove the parts in the order below.
Seat and fuel tank side panels Refer to “SEAT AND SIDE PANELS”.
Fuel tank Refer to “FUEL TANK”.
1 Rear carrier 1
2 Battery holding bracket 1
3 Battery lead cover 1
4 Battery lead 2 Disconnect.
CAUTION:
First disconnect the negative lead,
then disconnect the positive lead.
5 Battery 1
6 Starter relay ground lead 1
7 Taillight connector 2
3-6

INSP

8 Final drive gear case breather hose 1
9 Cylinder head breather hose 1
10 Clamp screw 1 Loosen.
11 Air filter case 1
12 Plastic band 1
13 Rear fender 1
procedure.
3-7

INSP
FUEL TANK

Fuel tank removal Remove the parts in the order below.
Seat and side panels Refer to “SEAT AND SIDE PANELS”.
Fuel tank cover Refer to “FRONT CARRIER, FRONT
BUMPER AND FRONT FENDER”.
1 Fuel hose 1 NOTE:
Before disconnecting the fuel hose,
turn the fuel cock to “OFF”.
2 Fuel cock 1
3 Fuel tank 1 NOTE:
When installing the fuel tank, pass the
fuel tank breather hose through the
hole in the handlebar protector.
4 Vacuum chamber breather hose 1
5 Plastic band 4
6 Rubber cover 1
procedure.
3-8

INSP
FOOTREST BOARDS ADJ
FOOTREST BOARDS

Footrest boards removal Remove the parts in the order below.
Fuel tank side panels Refer to “SEAT AND SIDE PANELS”.
1 Footrest 2
2 Left footrest board 1
3 Right footrest board 1
4 Left footrest bracket 1
5 Right footrest bracket 1
procedure.
3-9

INSP
VALVE CLEARANCE ADJUSTMENT ADJ
ENGINE
VALVE CLEARANCE ADJUSTMENT
NOTE:
● The valve clearance must be adjusted
when the engine is cool to the touch.

● Adjust the valve clearance when the pis-
ton is at the Top Dead Center (T.D.C.) on

the compression stroke.
1.Remove:
● Seat
● Front carrier
● Front fender
● Fuel tank
Refer to “SEAT, CARRIERS, FENDERS

AND FUEL TANK”.
2.Remove:
● Tappet cover (intake) 1
● Tappet cover (exhaust) 2
3.Disconnect:
● Spark plug cap 3
4.Remove:
● Spark plug
5.Remove:
● Recoil starter 1
3 - 10

INSP
6.Remove:
● Timing plug 1
7.Check:
● Valve clearance
Out of specification → Adjust.

Valve clearance (cold):
Intake:
0.06 ~ 0.10 mm
(0.0024 ~ 0.0039 in)
Exhaust:
0.16 ~ 0.20 mm
(0.0063 ~ 0.0079 in)
*********************************
Checking steps:
● Turn the crankshaft counterclockwise with
a wrench.
● Align the “T” mark 1 on the rotor with
the stationary pointer 2 on the crankcase
cover. When the “T” mark is aligned with
the stationary pointer, the piston is at the
Top Dead Center (T.D.C.).
NOTE:
● When the piston is at the Top Dead Center
(T.D.C.) on the compression stroke, there

should be clearance between the valve
stem tips and their respective rocker arm
adjusting screws.
● If there is no clearance, rotate the crank-
shaft counterclockwise one turn.
● Measure the valve clearance using a

feeler gauge 3.
*********************************
3 - 11

INSP
8.Adjust:
● Valve clearance
*********************************
Adjustment steps:
● Loosen the locknut 1.
● Insert a feeler gauge 2 between the
adjuster end and the valve end.
● Turn the adjuster 3 clockwise or counter-
clockwise with the valve adjusting tool 4
until the proper clearance is obtained.
Valve adjusting tool:

P/N. YM-08035, 90890-01311
● Hold the adjuster to prevent it from mov-

ing and then tighten the locknut.
Locknut:
20 Nm (2.0 m • kg, 14 ft • lb)
T.
R.
● Measure the valve clearance.
● If the clearance is incorrect, repeat the
above steps until the proper clearance is
obtained.
*********************************
9.Install:
● All removed parts
NOTE:
Install all removed parts in the reverse
order of their disassembly. Note the follow-
ing points.
10.Install:
● Recoil starter LT
10 Nm (1.0 m • kg, 7.2 ft • lb)

T.
R.
● Spark plug 18 Nm (1.8 m • kg, 13 ft • lb)

T.
R.
● Tappet covers
10 Nm (1.0 m • kg, 7.2 ft • lb)
T.
R.
NOTE:
Install the tappet covers with the ridge fac-
ing up Å.
3 - 12

VALVE CLEARANCE ADJUSTMENT/TIMING CHAIN INSP
ADJUSTMENT/IDLING SPEED ADJUSTMENT ADJ
11.Install:
● Fuel tank
● Front fender
● Front carrier
● Seat

AND FUEL TANK”.
TIMING CHAIN ADJUSTMENT

Adjustment free.
IDLING SPEED ADJUSTMENT

1.Start the engine and let it warm up for
several minutes.
2.Remove:
● Seat
● Fuel tank side panels

AND FUEL TANK”.
3.Attach:
● Inductive tachometer or engine tachometer
(to the spark plug lead)
Inductive tachometer:
P/N. YU-8036-A
Engine tachometer:
P/N. 90890-03113
4.Check:
● Engine idling speed
Engine idling speed:

1,450 ~ 1,550 r/min
3 - 13

IDLING SPEED ADJUSTMENT/ INSP
THROTTLE LEVER FREE PLAY ADJUSTMENT ADJ
5.Adjust:
● Engine idling speed
*********************************
Adjustment steps:
● Turn the throttle stop screw 1 in or out
until the specified idling speed is
obtained.
Idling speed becomes

Turning in
higher.
Idling speed becomes
Turning out
lower.
*********************************
6.Detach:
● Inductive or engine tachometer
7.Adjust:
● Throttle lever free play
Refer to “THROTTLE LEVER FREE PLAY

ADJUSTMENT”.
Throttle lever free play:

3 ~ 5 mm (0.12 ~ 0.20 in)
8.Install:
● Fuel tank side panels
● Seat

AND FUEL TANK”.
THROTTLE LEVER FREE PLAY

ADJUSTMENT
NOTE:
Engine idling speed should be adjusted
properly before adjusting the throttle lever
free play.
3 - 14

INSP
THROTTLE LEVER FREE PLAY ADJUSTMENT ADJ
1.Check:
● Throttle lever free play a
Throttle lever free play:

3 ~ 5 mm (0.12 ~ 0.20 in)
2.Remove:
● Seat
● Fuel tank side panel (right)

AND FUEL TANK”.
3.Adjust:
● Throttle lever free play
*********************************
Adjustment steps:
First step:
● Pull back the adjuster cover 1.
● Loosen the locknut 2 on the carburetor
side.
● Turn the adjuster 3 in or out until the cor-
rect free play is obtained.
Turning in Free play is increased.

Turning out Free play is decreased.
● Tighten the locknut 2.

● Push in the adjuster cover 1.
NOTE:
If the free play cannot be adjusted here,
adjust it at the throttle lever side of the
cable.
Second step:
Turning in Free play is increased.
Turning out Free play is decreased.
3 - 15

THROTTLE LEVER FREE PLAY ADJUSTMENT/ INSP
SPEED LIMITER ADJUSTMENT ADJ
WARNING
After adjusting the free play, turn the handle-
bar to the right and left to make sure that the
engine idling speed does not increase.
*********************************
4.Install:
● Seat

AND FUEL TANK”.
SPEED LIMITER ADJUSTMENT

The speed limiter keeps the carburetor
throttle from becoming fully-opened even
when the throttle lever is applied to the
maximum position. Screwing in the
adjuster stops the engine speed from
increasing.
1.Check:
● Speed limiter length a
Speed limiter length:

12 mm (0.47 in)
2.Adjust:
● Speed limiter length
*********************************
Speed limiter length adjustment steps:
● Turn the adjuster 2 in or out until the
specified speed limiter length is obtained.
3 - 16

SPEED LIMITER ADJUSTMENT/ INSP
STARTER LEVER FREE PLAY ADJUSTMENT ADJ
Speed limiter length is
Turning in
decreased.
Speed limiter length is
Turning out
increased.
● Tighten the locknut.
WARNING
● Particularly for a beginner rider, the speed
limiter should be screwed in completely.
Screw it out little by little as their riding
technique improves. Never remove the
speed limiter for a beginning rider.
● For proper throttle lever operation do not
turn out the adjuster more than 12 mm
(0.47 in). Also, always adjust the throttle
lever free play to 3 ~ 5 mm (0.12 ~ 0.20 in).
*********************************
STARTER LEVER FREE PLAY

ADJUSTMENT
1.Check:
● Starter lever free play a
Starter lever free play:

5.5 ~ 14.2 mm (0.22 ~ 0.56 in)
2.Remove:
● Seat
● Fuel tank side panel (left)

AND FUEL TANK”.
3.Adjust:
● Starter lever free play
*********************************
Adjustment steps:
3 - 17

STARTER LEVER FREE PLAY ADJUSTMENT/ INSP
SPARK PLUG INSPECTION ADJ
Turning in Free play increased.
Turning out Free play decreased.
WARNING
After adjusting the free play, turn the han-
dlebar to right and left, and make sure that
the engine idling speed does not increase.
*********************************
4.Install:
● Seat

AND FUEL TANK”.
SPARK PLUG INSPECTION

1.Remove:
● Seat

AND FUEL TANK”.
2.Remove:
● Spark plug
3.Inspect:
● Spark plug type
Incorrect → Replace.
Standard spark plug:

DR8EA/NGK (For CDN, GB, F, CH)
D8EA/NGK (For Oceania)
X24ES-U/DENSO (For Oceania)
4.Inspect:
● Electrode 1
Wear/damage → Replace.
● Insulator 2
Abnormal color → Replace.

Normal color is a medium-to-light tan color.
5.Clean the spark plug with a spark plug
cleaner or wire brush.
3 - 18

SPARK PLUG INSPECTION/ INSP
IGNITION TIMING CHECK ADJ
6.Measure:
● Plug gap a
Use a wire gauge or feeler gauge.

Out of specification → Regap.
Spark plug gap:

0.6 ~ 0.7 mm (0.024 ~ 0.028 in)
7.Tighten:
T.
R.
NOTE:
Before installing a spark plug, clean the
gasket surface and plug surface.
8.Install:
● Seat

AND FUEL TANK”.
IGNITION TIMING CHECK

NOTE:
Engine idling speed and throttle cable free
play should be adjusted properly before
checking the ignition timing.
1.Remove:
● Seat

AND FUEL TANK”.
2.Attach:
● Inductive tachometer or engine tachometer
● Timing light
(to spark plug lead)

Inductive tachometer:
P/N. YU-8036-A
Engine tachometer:
P/N. 90890-03113
Timing light:
P/N. YM-33277-A, 90890-03141
3 - 19

IGNITION TIMING CHECK/ INSP
COMPRESSION PRESSURE MEASUREMENT ADJ
3.Check:
● Ignition timing
*********************************
Checking steps:
● Warm up the engine and keep it at the
specified speed.
Engine speed:
1,450 ~ 1,550 r/min
● Remove the recoil starter 1.

● Remove the timing plug 2.
● Visually check the stationary pointer 3 to
verify it is within the required firing range
4 indicated on the flywheel.
Incorrect firing range → Check the pulser
coil assembly.
● Install the timing plug.
● Install the recoil starter.
Recoil starter bolt:

T. 10 Nm (1.0 m • kg, 7.2 ft • Ib)
LOCTITE®
R.
*********************************
4.Detach:
● Timing light
● Inductive tachometer or engine tachome-
ter
5.Install:
● Seat
AND FUEL TANK”.
COMPRESSION PRESSURE
MEASUREMENT
NOTE:
Insufficient compression pressure will
result in a loss of performance.
3 - 20

INSP
COMPRESSION PRESSURE MEASUREMENT ADJ
1.Check:
● Valve clearance

Refer to “VALVE CLEARANCE ADJUST-
MENT”.
several minutes.
3.Stop the engine.
4.Remove:
● Seat

AND FUEL TANK”.
5.Remove:
● Spark plug
6.Attach:
● Adapter
● Compression gauge 1
Compression gauge:
P/N. YU-33223, 90890-03081
Adapter:
P/N. YU-33223-3, 90890-04082
7.Measure:
● Compression pressure
Above the maximum pressure:

Inspect the cylinder head, valve surfaces,
and piston crown for carbon deposits.
Below the minimum pressure:
Squirt a few drops of oil into the affected
cylinder and measure again.
● Refer to the table below.
Compression pressure
(with oil introduced into cylinder)
Reading Diagnosis
Higher than
Worn or damaged pistons
without oil
Defective ring(s), valves,
Same as
cylinder head gasket or
without oil
piston is possible.
3 - 21

COMPRESSION PRESSURE MEASUREMENT/ INSP
ENGINE OIL LEVEL INSPECTION ADJ
Compression pressure (at sea level):
Standard:
1,400 kPa (14 kg/cm2, 203 psi)
Minimum:
1,218 kPa (12.2 kg/cm2, 177 psi)
Maximum:
1,568 kPa (15.7 kg/cm2, 227 psi)
*********************************
Measurement steps:
● Crank over the engine with the electric
starter (be sure the battery is fully
charged) with the throttle wide-open until
the compression reading on the gauge
stabilizes.
WARNING
When cranking the engine, ground the
spark plug lead to prevent sparking.
*********************************
8.Install:
T.
R.
9.Remove:
● Seat

AND FUEL TANK”.
ENGINE OIL LEVEL INSPECTION
1.Place the machine on a level surface.
2.Remove:
● Engine side panel

AND FUEL TANK”.
3.Inspect:
● Engine oil level
Oil level should be between the maximum

1 mark.
Oil level low → Add oil to the proper level.
NOTE:
Do not screw the dipstick 2 in when
inspecting the oil level.
Recommended oil:
Follow the left chart.
3 - 22

ENGINE OIL LEVEL INSPECTION/ INSP
ENGINE OIL REPLACEMENT ADJ
NOTE:
0° 10° 30° 50° 70° 90° 110°F Recommended oil classification:
YAMALUBE 4 (20W40) or SAE 20W40 API Service “SE”, “SF” type or equivalent
(e.g. “SF–SE–CC”, “SF–SE–SD” etc.)
SAE 5W30
CAUTION:
-20° -10° 0° 10° 20° 30° 40°C Do not allow foreign material to enter the
crankcase.
several minutes.
5.Stop the engine and inspect the oil level
again.
NOTE:
Wait a few minutes until the oil settles
before inspecting the oil level.
WARNING
Never remove the dipstick just after high
speed operation because the heated oil
could spurt out. Wait until the oil cools
down before removing the dipstick.
6.Install:
● Engine side panel
ENGINE OIL REPLACEMENT

several minutes.
2.Stop the engine and place an oil pan
under the engine.
3.Remove:
● Seat
● Engine side cover

AND FUEL TANK”.
3 - 23

INSP
4.Remove:
● Engine oil filler plug (dipstick) 1
● Engine oil drain bolt 2
Drain the crankcase of its oil.
5.If the oil filter cartridge is also to be

replaced, perform the following proce-
dure.
*********************************
Replacement steps:
● Remove the oil filter cartridge 1 with an
oil filter wrench 2.
Oil filter wrench:

P/N. YU-38411, 90890-01426
● Lubricatethe O-ring 3 of the new oil filter

cartridge with a thin coat of engine oil.
CAUTION:
Make sure that the O-ring 3 is positioned
correctly in the groove of the oil filter car-
tridge.
● Tighten the new oil filter cartridge to spec-
ification with an oil filter wrench.
Oil filter cartridge:

17 Nm (1.7 m • kg, 12 ft • lb)
T.
R.
*********************************
6.Install:
● Engine oil drain bolt 1
32 Nm (3.2 m • kg, 23 ft • lb)

T.
R.
3 - 24

INSP
7.Fill:
● Crankcase
Refer to “ENGINE OIL LEVEL INSPEC-

TION”.
Oil quantity:
Periodic oil change:
2.3 L (2.0 Imp qt, 2.4 US qt)
With oil filter replacement:
2.4 L (2.1 Imp qt, 2.5 US qt)
Total amount:
2.6 L (2.3 Imp qt, 2.7 US qt)
8.Install:
● Engine oil filler plug
9.Warm up the engine for a few minutes,

then stop the engine.
10.Inspect:
● Engine
(for engine oil leaks)

● Oil level
Refer to “ENGINE OIL LEVEL INSPEC-

TION”.
11.Check:
● Engine oil pressure
*********************************
● Slightly loosen the oil gallery bolt 1.
● Start the engine and keep it idling until
engine oil starts to seep from the oil gal-
lery bolt. If no engine oil comes out after
one minute, turn the engine off so that it
will not seize.
● Check the engine oil passages, the oil fil-
ter cartridge and the oil pump for damage
or leakage. Refer to “OIL PAN AND OIL
PUMP” in CHAPTER 4.
● Start the engine after solving the prob-
lem(-s) and check the engine oil pressure
again.
● Tighten the oil gallery bolt to specifica-
tion.
Oil gallery bolt:

7 Nm (0.7 m • kg, 5.1 ft • lb)
T.
R.
*********************************
12.Install:
● Seat

AND FUEL TANK”.
3 - 25

INSP
AIR FILTER CLEANING ADJ
AIR FILTER CLEANING
NOTE:
There is a check hose 1 at the bottom of
the air filter case. If dust and/or water col-
lects in this hose, clean the air filter element
and air filter case.
1.Remove:
● Seat
● Fuel tank cover

AND FUEL TANK”.
2.Disconnect:
● Cylinder head breather hose 1
3.Remove:
● Final drive gear case breather hose 2
● Air filter case cover 3
4.Remove:
● Air filter element assembly 1
● Air filter element cap
● Air filter element
NOTE:
When removing the air filter element, rotate
the air filter element cap 1/4 of a turn and
remove the element.
2 Air filter element cap

3 Air filter element
CAUTION:
Never operate the engine with the air filter
element removed. This will allow unfiltered
air to enter, causing rapid wear and possible
engine damage. Additionally, operation
without the filter element will affect carbu-
retor tuning with subsequent poor perfor-
mance and possible engine overheating.
5.Inspect:
Damaged → Replace.
3 - 26

INSP
AIR FILTER CLEANING ADJ
6.Clean:
*********************************
Cleaning steps:
● Wash the element gently, but thoroughly
in solvent.
WARNING
Use a cleaning solvent which is designed to
clean parts only. Never use gasoline or low
flash point solvents as they may cause a
fire or explosion.
● Squeezethe excess solvent out of the ele-
ment and let it dry.
CAUTION:
Do not twist or wring out the element. This
could damage the foam material.
● Apply engine oil to the element.
● Squeeze out the excess oil.
NOTE:
The element should be wet but not drip-
ping.
*********************************
7.Install:
● Air filter case cover
NOTE:
● Insert the lobes 1 on the filter element
into the receptacles 2 on the filter case.

● To prevent air leaks make sure that the
sealing surface of the element matches

the sealing surface of the case.
8.Install:
● Final drive gear case breather hose 1
9.Connect:
● Cylinder head breather hose 2
10.Install:
● Fuel tank cover
● Seat

AND FUEL TANK”.
3 - 27

INSP
COOLANT LEVEL INSPECTION ADJ
COOLANT LEVEL INSPECTION
2.Remove:
● Seat
3.Inspect:
● Coolant level
The coolant level should be between the

minimum level mark a and maximum
level mark b.
Below the minimum level mark → Add the
recommended coolant to the proper level.
CAUTION:
● Adding water instead of coolant lowers
the antifreeze content of the coolant. If
water is used instead of coolant, check
and if necessary, correct the antifreeze
concentration of the coolant.
● Use only distilled water. However, soft
water may be used if distilled water is not
available.
4.Start the engine, warm it up for several
minutes, and then turn it off.
5.Inspect:
● Coolant level
NOTE:
Before inspecting the coolant level, wait a
few minutes until the coolant has settled.
6.Install:
● Seat

AND FUEL TANK”.
3 - 28

INSP
COOLANT REPLACEMENT ADJ
COOLANT REPLACEMENT
1.Remove:
● Seat
● Front carrier
● Front fender
Refer to “SEAT, CARPIERS, FENDERS

AND FUEL TANK”.
● Left footrest board
Refer to “FOOTREST BOARDS”.
2.Remove:
● Engine skid plate (rear) 1
3.Remove:
● Plastic band 1
● Coolant reservoir bolts 2
● Coolant reservoir cap 3
4.Disconnect:
● Coolant reservoir breather hose 4
5.Drain:
● Coolant
(from the coolant reservoir)

6.Connect:
● Coolant reservoir breather hose
7.Install:
● Coolant reservoir bolts
● Plastic band
3 - 29

INSP
8.Remove:
● Radiator cap 1
WARNING
A hot radiator is under pressure. Therefore,
do not remove the radiator cap when the
engine is hot. Scalding hot fluid and steam
may be blown out, which could cause seri-
ous injury. When the engine has cooled,
open the radiator cap as follows:
Place a thick rag or a towel over the radia-
tor cap and slowly turn the radiator cap
counterclockwise toward the detent to
allow any residual pressure to escape.
When the hissing sound has stopped, turn
the radiator cap counterclockwise while
pressing down on it and then remove it.
9.Remove:
● Coolant drain bolt (cylinder) 1
(along with the copper washer)

● Coolant drain bolt (water pump) 2
(along with the copper washer)

10.Drain:
● Coolant
11.Check:
● Copper washer 1
● Coolant drain bolt 2
Damage → Replace.
12.Install:
● Coolant drain bolt (water pump)
10 Nm (1.0 m • kg, 7.2 ft • lb)

T.
R.
● Coolant drain bolt (cylinder)

10 Nm (1.0 m • kg, 7.2 ft • lb)
T.
R.
3 - 30

INSP
13.Fill:
● Cooling system
(with the specified amount of the recom-

mended coolant)
Recommended antifreeze
High-quality ethylene glycol
antifreeze containing corrosion
inhibitors for aluminum engines
Mixing ratio
1:1 (antifreeze:water)
Quantity
Total amount
1.1 L
(0.97 lmp qt, 1.16 US qt)
Coolant reservoir capacity
0.25 L
(0.22 lmp qt, 0.26 US qt)
Handling notes for coolant

Coolant is potentially harmful and should
be handled with special care.
WARNING
● If coolant splashes in your eyes, thor-
oughly wash them with water and con-
sult a doctor.
● If coolant splashes on your clothes,
quickly wash it away with water and then
with soap and water.
● If coolant is swallowed, induce vomiting
and get immediate medical attention.
CAUTION:
● Adding water instead of coolant lowers
the antifreeze content of the coolant. If
water is used instead of coolant, check,
and if necessary, correct the antifreeze
concentration of the coolant.
● Use only distilled water. However, soft
water may be used if distilled water is not
available.
● If coolant comes into contact with
painted surfaces, immediately wash them
with water.
● Do not mix different types of antifreeze.
14.Install:
●Radiator cap
3 - 31

INSP
15.Fill:
● Coolant reservoir
(with the recommended coolant to the

maximum level mark a)
16.Install:
● Coolant reservoir cap
17.Start the engine, warm it up for several

minutes, and then turn it off.
18.Inspect:
● Coolant level
Refer to “CHECKING THE COOLANT

LEVEL”.
NOTE:
Before inspecting the coolant level, wait a
few minutes until the coolant has settled.
19.Install:
● Engine skid plate (rear)
● Left footrest board

● Front fender
● Front carrier
● Seat

AND FUEL TANK”.
3 - 32

COOLANT TEMPERATURE INDICATOR LIGHT CHECK/ INSP
V-BELT INSPECTION ADJ
COOLANT TEMPERATURE INDICATOR
LIGHT CHECK
1 Coolant temperature indicator light
V-BELT INSPECTION
1.Remove:
● Right footrest board
● Crankcase cover (right)
Refer to “PRIMARY AND SECONDARY

SHEAVES” in CHAPTER 4.
2.Inspect:
● V-belt 1
Cracks/wear/scaling/chipping → Replace.
Oil/grease → Check primary sheave and
secondary sheave.
3.Measure:
● V-belt width 2
Out of specification → Replace.
V-belt width:
29.3 mm (1.15 in)
<Limit>: 27.3 mm (1.07 in)
3 - 33

INSP
V-BELT INSPECTION ADJ
4.Replace:
● V-belt
*********************************
Replacing steps:
● Install
the bolts 1 (90101-06016) into the
secondary fixed sheave hold.
NOTE:
Tightening the bolts 1 will push the sec-
ondary sliding sheave away, causing the
gap between the secondary fixed and slid-
ing sheaves to widen.
● Remove the V-belt 1 from the primary
sheave and secondary sheave.
● Install the V-belt.

NOTE:
Install the V-belt so that its arrow faces the
direction shown in the illustration.
● Remove the bolts.
*********************************
3 - 34

FRONT BRAKE ADJUSTMENT/ INSP
REAR BRAKE ADJUSTMENT ADJ
CHASSIS
FRONT BRAKE ADJUSTMENT
1.Check:
● Brake lever free play a
Out of specification → Bleed the front

brake system.
Refer to “AIR BLEEDING (HYDRAULIC
BRAKE SYSTEM)”.
Free play:
0 mm (0 in)
(at brake lever end)
REAR BRAKE ADJUSTMENT
WARNING
Always adjust both the brake pedal and the
rear brake lever whenever adjusting the
rear brake.
1.Check:
● Rear brake pedal free play a
Out of specification → Bleed the rear

brake system.
BRAKE SYSTEM)”.
Rear brake pedal free play:

5 ~ 7 mm (0.2 ~ 0.3 in)
2.Check:
● Rear brake lever free play b
Rear brake lever free play:

0.5 ~ 2 mm (0.02 ~ 0.08 in)
3 - 35

INSP
3.Check:
● Rear brake pedal height a
Rear brake pedal height:

53 ~ 60 mm (2.09 ~ 2.36 in)
4.Adjust:
● Rear brake lever free play
● Rear brake pedal height
*********************************
Adjustment steps:
● Loosen the locknut (handlebar) 1 and
fully screw in the brake lever cable
adjuster (handlebar) 2 until the clearance
a is within the specified limits.
Clearance a:
0 mm (0 in)
● Remove the rear brake master cylinder

cover 3.

● Turn the adjusting bolt 5 until the brake
pedal height is within the specified limits.
Brake pedal height:

53 ~ 60 mm (2.09 ~ 2.36 in)

NOTE:
When adjusting the brake pedal height
make sure the locknut-to-adjusting bolt
clearance b does not exceed 2 mm
(0.08 in).
3 - 36

INSP
● Pullup the brake outer cable and turn the
brake cable adjusting (nut) 7 until the
clearance c is within the specified limits.
Clearance c:
1 mm (0.04 in)
NOTE:
Make sure the pin 8 is all the way to the
right of the link plate hole.
● Holdthe adjusting nut 7 and tighten the
locknut 6.
● Turnthe brake lever cable adjuster (han-

dlebar) 2 until the rear brake lever free
play d is within the specified limits.
Rear brake lever free play:

0.5 ~ 2 mm (0.02 ~ 0.08 in)
● Tighten the locknut (handlebar) 1.

● Adjust the select lever control cable.
Refer to “SELECT LEVER CONTROL
CABLE AND SHIFT ROD ADJUSTMENT”.
● Install the rear brake master cylinder
cover.
WARNING
After this adjustment is performed, lift the
front and rear wheels off the ground by
placing a block under the engine, and spin
the rear wheels to ensure there is no brake
drag. If any brake drag is noticed perform
the above steps again.
*********************************
3 - 37

INSP
BRAKE FLUID LEVEL INSPECTION ADJ
BRAKE FLUID LEVEL INSPECTION
NOTE:
When inspecting the brake fluid level, make
sure that the top of the brake fluid reservoir
top is horizontal.
2.Remove: (rear brake)
● Front carrier
● Front fender panel

AND FUEL TANK”.
3.Inspect:
● Brake fluid level
Fluid level is under “LOWER” level line 1

→ Fill up.
Recommended brake fluid:

DOT 4
NOTE:
Å If DOT 4 is not available, DOT 3 can be used.
Å Front brake
ı Rear brake
CAUTION:
Brake fluid may erode painted surfaces or
plastic parts. Always clean up spilled fluid
immediately.
WARNING
ı
● Use only the designed quality brake fluid:
otherwise, the rubber seals may deterio-
rate, causing leakage and poor brake per-
formance.
● Refill with the same type of brake fluid;
mixing fluids may result in a harmful
chemical reaction and lead to poor perfor-
mance.
● Be careful that water does not enter the
master cylinder when refilling. Water will
significantly lower the boiling point of the
fluid and may result in a vapor lock.
4.Install: (rear brake)
● Front carrier

AND FUEL TANK”.
3 - 38

FRONT BRAKE PAD INSPECTION/REAR BRAKE PAD INSP
INSPECTION/BRAKE HOSE INSPECTION ADJ
FRONT BRAKE PAD INSPECTION
1.Remove:
● Front wheels
2.Inspect:
● Brake pad
Wear indicators 1 almost touch the brake

disc → Replace the brake pads as a set.
Refer to “FRONT AND REAR BRAKES” in
CHAPTER 8.
Brake pad wear limit a:

1 mm (0.04 in)
3.Operate the brake lever.

4.Install:
● Front wheels
REAR BRAKE PAD INSPECTION

1.Remove:
● Rear wheel (left)
2.Inspect:
● Brake pad
Wear indicator groove 1 almost disap-

peared → Replace the brake pads as a set.
Refer to “FRONT AND REAR BRAKES” in
CHAPTER 8.
Brake pad wear limit a:

1 mm (0.04 in)
3.Operate the brake lever or brake pedal.

4.Install:
● Rear wheel (left)
BRAKE HOSE INSPECTION

1.Remove:
● Seat
● Front carrier
● Front fender

AND FUEL TANK”.
3 - 39

BRAKE HOSE INSPECTION/ INSP
AIR BLEEDING (HYDRAULIC BRAKE SYSTEM) ADJ
2.Inspect:
● Front brake hoses 1
● Rear brake hoses 2
Cracks/wear/damage → Replace.
3.Check:
● Brake hose clamp
Loosen → Tighten.
4.Hold the machine in an upright position
and apply the front or rear brake.
5.Check:
● Brake hoses
Active the brake lever several times.

Fluid leakage → Replace the hose.
Refer to “FRONT BRAKE” and “REAR
BRAKE” in CHAPTER 7.
6.Install:

● Front fender
● Front carrier
● Seat

AND FUEL TANK”.
AIR BLEEDING (HYDRAULIC BRAKE

SYSTEM)
WARNING
Bleed the brake system if:
● The system has been disassembled.
● A brake hose or brake pipe have been
loosened or removed.
● The brake fluid has been very low.
● The brake operation has been faulty.
A loss of braking performance may occur if

the brake system is not properly bled.
1.Bleed:
● Brake system
*********************************
Air bleeding steps:
a. Add the proper brake fluid to the reser-
voir.
3 - 40

INSP
AIR BLEEDING (HYDRAULIC BRAKE SYSTEM) ADJ
Å b. Install the diaphragm. Be careful not to
spill any fluid or allow the reservoir to
overflow.
c. Connect the clear plastic hose 1 tightly
to the caliper bleed screw 2.
Å Front
ı Rear
d. Place the other end of the hose into a
container.
e. Slowly apply the brake lever or pedal
ı several times.
f. Pull the lever in or push down on the
pedal and hold it.
g. Loosen the bleed screw and allow the
lever or pedal to travel towards its limit.
h. Tighten the bleed screw when the lever
or pedal limit has been reached, then
release the lever or pedal.
i. Repeat steps (e) to (h) until all the air
bubbles have disappeared from the fluid.
j. Tighten the bleed screw.
Bleed screw:
6 Nm (0.6 m • kg, 4.3 ft • lb)
T.
R.
NOTE:
If bleeding is difficult, it may be necessary
to let the brake fluid settle for a few hours.
Repeat the bleeding procedure when the
tiny bubbles in the system have disap-
peared.
k. Add brake fluid to the proper level.
Refer to “BRAKE FLUID LEVEL INSPEC-
TION”.
WARNING
Check the operation of the brake after
bleeding the brake system.
*********************************
3 - 41

SELECT LEVER CONTROL CABLE AND INSP
SHIFT ROD ADJUSTMENT ADJ
SELECT LEVER CONTROL CABLE AND
SHIFT ROD ADJUSTMENT
1 NEUTRAL
2 HIGH
3 LOW
4 REVERSE
5 PARK
6 Control cable
7 Select lever shift rod
WARNING
Before moving the select lever, bring the
machine to a complete stop and return the
throttle lever to its closed position. Other-
wise the transmission may be damaged.
1.Adjust:
● Rear brake pedal free play
Refer to “REAR BRAKE LEVER AND

PEDAL ADJUSTMENT”.
2.Adjust:
● Select lever control cable
● Select lever shift rod
*********************************
Select lever control cable and select lever
shift rod adjustment steps:
Control cable:
● Make sure the select lever is in NEUTRAL.
● Adjust the control cable so there is zero
free play in the cable. When the adjust-
ment is correct, slack in the return spring
1 will be taken up.
NOTE:
In some cases it will be necessary to further
adjust the cable with the locknuts 2
arrangement that holds the cable to its
mount.
● When the brake begins to work “a = 20 ~

30 mm (0.8 ~ 1.2 in)”, verify that the select
lever can be shifted to REVERSE from
NEUTRAL, to PARK from REVERSE and to
NEUTRAL from REVERSE.
● Before the brake begins to work “a = 0 ~
20 mm (0 ~ 0.8 in)”, verify that the select
lever cannot be shifted to REVERSE from
NEUTRAL, to REVERSE from PARK and to
NEUTRAL from REVERSE.
3 - 42

SELECT LEVER CONTROL CABLE AND SHIFT ROD INSP
ADJUSTMENT/FINAL GEAR OIL LEVEL INSPECTION ADJ
● Check that locknuts 2 are tightened cor-
rectly.
● If the operation of the select lever is incor-
rect, adjust the select lever control cable
3 with the adjuster 4.
Select lever shift rod:

● Make sure the select lever is in NEUTRAL.
● Loosen both locknuts 1.
● Adjust the shift rod length for smooth and
correct shifting.
● Tighten the locknuts 1.
*********************************
FINAL GEAR OIL LEVEL INSPECTION

1.Place the machine on a level place.
2.Remove:
● Oil filler bolt 1
3.Inspect:
● Oil level
Oil level should be up to the bottom brim

2 of the hole.
Oil level low → Add oil to the proper level.
Recommended oil:
SAE 80 API “GL-4” Hypoid gear oil
CAUTION:
Take care not allow foreign material to
enter the final gear case.
4.Install:
● Oil filler bolt 23 Nm (2.3 m • kg, 16 ft • lb)
T.
R.
3 - 43

INSP
FINAL GEAR REPLACEMENT ADJ
FINAL GEAR REPLACEMENT
2.Remove:
● Final gear case protector 1
3.Place a receptacle under the final gear

case.
4.Remove:
● Oil filler bolt
● Drain plug 1
5.Drain:
● Final gear oil
6.Install:
● Drain plug 23 Nm (2.3 m • kg, 16 ft • lb)
T.
R.
NOTE:
Check the gasket (drain plug). If it is dam-
aged, replace it with a new one.
7.Fill:
● Final gear case

0.19 L (0.17 Imp qt, 0.20 US qt)
Total amount:
0.22 L (0.19 Imp qt, 0.23 US qt)
Recommended oil:
SAE80 API “GL-4” Hypoid gear oil
CAUTION:
Take care not to allow foreign material to
8.Inspect:
● Oil level
Refer to “FINAL GEAR OIL LEVEL INSPEC-

TION”.
9.Install:
T.
R.
● Final gear case protector
23 Nm (2.3 m • kg, 16 ft • lb)

T.
R.
3 - 44

DIFFERENTIAL GEAR OIL INSPECTION/ INSP
DIFFERENTIAL GEAR OIL REPLACEMENT ADJ
DIFFERENTIAL GEAR OIL INSPECTION
2.Remove:
● Oil filter bolt
● Oil drain plug 1
3.Drain:
● Differential gear oil
4.Install:
● Oil drain plug 10 Nm (1.0 m • kg, 7 ft • lb)
T.
R.
5.Fill:
Recommended oil:
SAE 80 API “GL-4” Hypoid gear
oil
Oil quantity (periodic oil change):
0.35 L (0.31 Imp qt, 0.37 US qt)
CAUTION:
Take care not allow foreign material to
6.Install:
● Oil filter bolt 23 Nm (2.3 m • kg, 16 ft • lb)
T.
R.
NOTE:
If gear oil is filled to the brim of the oil filler
hole, oil may start leaking from the differen-
tial gear case breather hose. Therefore,
check the quantity of the oil, not its level.
DIFFERENTIAL GEAR OIL REPLACEMENT

2.Place a receptacle under the differential
gear case.
3.Remove:
● Oil filler bolt
● Drain plug 1
3 - 45

DIFFERENTIAL GEAR OIL REPLACEMENT/
CONSTANT VELOCITY JOINT DUST BOOT INSPECTION/ INSP
STEERING SYSTEM INSPECTION ADJ
4.Drain:
5.Install:
● Drain plug 10 Nm (1.0 m • kg, 7 ft • lb)
T.
R.
NOTE:
Check the gasket (drain plug). If it is dam-
aged, replace it with new one.
6.Fill:
● Differential gear case

0.35 L (0.31 Imp qt, 0.37 US qt)
Total amount:
0.40 L (0.35 Imp qt, 0.42 US qt)
Recommended oil:
SAE 80 API “GL-4” Hypoid gear oil
NOTE:
If gear oil is filled to the brim of the oil filler
hole, oil may start leaking from the differen-
tial gear case breather hose. Therefore,
check the quantity of the oil, not its level.
CAUTION:
Take care not to allow foreign material to
enter the differential gear case.
7.Install:
T.
R.
CONSTANT VELOCITY JOINT DUST BOOT

INSPECTION
1.Inspect:
● Dust boots 1
Damage → Replace.
Refer to “DIFFERENTIAL GEAR AND CON-
STANT VELOCITY JOINT” in CHAPTER 6.
STEERING SYSTEM INSPECTION

2.Check:
● Steering assembly bushings
Move the handlebar up and down, and/or

back and forth.
Excessive play → Replace the steering
stem bushings.
3 - 46

STEERING SYSTEM INSPECTION/ INSP
TOE-IN ADJUSTMENT ADJ
3.Check:
● Tie-rod ends
Turn the handlebar to the left and/or right

until it stops completely, then move the
handlebar from the left to the right
slightly. Tie-rod end has any vertical play
→ Replace the tie-rod end(s).
4.Raise the front end of the machine so that

there is no weight on the front wheels.
5.Check:
● Ball joints and/or wheel bearings
Move the wheels laterally back and forth.

Excessive free play → Replace the front
arms (upper and lower) and/or wheel
bearings.
TOE-IN ADJUSTMENT
2.Measure:
● Toe-in
Toe-in:
0 ~ 10 mm (0 ~ 0.40 in)
*********************************
Toe-in measurement steps:
NOTE:
Before measuring the toe-in, make sure that
the tire pressure is correct.
● Mark both front tire tread centers.
● Raisethe front end of the machine so that
there is no weight on the front tires.
3 - 47

INSP
TOE-IN ADJUSTMENT ADJ
● Face the handlebar straight ahead.
● Measure the width Å between the marks.
● Rotate the front tires 180˚ until the marks
are exactly opposite one another.
● Measure the width ı between the marks.
● Calculate the toe-in using the formula
given below.
Toe-in = ı – Å
● If the toe-in is incorrect, adjust it.

*********************************
3.Adjust:
● Toe-in
WARNING
● Be sure that both tie-rods are turned the
same amount. If not, the machine will
drift right or left even though the handle-
bar is positioned straight. This may lead
to mishandling and an accident.
● After setting the toe-in to specification, run
the machine slowly for some distance with
both hands lightly holding the handlebar
and check that the handlebar responds cor-
rectly. If not, turn either the right or left tie-
rod within the toe-in specification.
*********************************
Adjustment steps:
● Mark both tie-rods ends.
This reference point will be needed during
adjustment.
● Loosen the locknuts (tie-rod end) 1 of
both tie-rods.
● The same number of turns should be
given to both the right and left tie-rods 2
until the specified toe-in is obtained. This
is to keep the length of the rods the same.
● Tighten the rod end locknuts of both tie rods.
Locknut (rod end):

15 Nm (1.5 m • kg, 11 ft • lb)
T.
R.
NOTE:
Adjust the rod ends so that A and B are
equal.
*********************************
3 - 48

FRONT SHOCK ABSORBER ADJUSTMENT/REAR INSP
SHOCK ABSORBER ADJUSTMENT/TIRE INSPECTION ADJ
FRONT SHOCK ABSORBER ADJUSTMENT
WARNING
Always adjust both front shock absorber
spring preload to the same setting. Uneven
adjustment can cause poor handling and
loss of stability.
1.Adjust:
● Spring preload
Turn the adjuster 1 to increase or

decrease the spring preload.
Standard position: 2
Minimum (Soft) position: 1
Maximum (Hard) position: 5
REAR SHOCK ABSORBER ADJUSTMENT

1.Adjust:
● Spring preload
Turn the adjuster 1 to increase or

decrease the spring preload.
NOTE:
The spring preload of the rear shock
absorber can be adjusted to suit the rider’s
preference, weight, and the riding condi-
tions.
Standard position: 2
Minimum (Soft) position: 1
Maximum (Hard) position: 5
TIRE INSPECTION
WARNING
This model is equipped with low pressure
tires. It is important that they be inflated
correctly and maintained at the proper
pressures.
● TIRE CHARACTERISTICS
3 - 49

INSP
TIRE INSPECTION ADJ
1)Tire characteristics influence the handling
of ATV’s. The tires listed below have
been approved by Yamaha Motor Co.,
Ltd. for this model. If other tire combina-
tions are used, they can adversely affect
your machine’s handling characteristics
and are therefore not recommended.
Manufacturer Size Type
DUNLOP
AT25 × 8-12 KT123
(For CDN, GB, F, CH)
Front
CHENG SHIN
AT25 × 8-12 C828
(For Oceania)
DUNLOP
AT25 × 10-12 KT127
(For CDN, GB, F, CH)
Rear
CHENG SHIN
AT25 × 10-12 C828
(For Oceania)
● TIRE PRESSURE
1)Recommended tire pressure
Front 25 kPa (0.25 kg/cm2, 3.6 psi)
Rear 25 kPa (0.25 kg/cm2, 3.6 psi)
2)Tire pressure below the minimum specifi-
cation could cause the tire to dislodge
from the rim under severe riding condi-
tions.
The following are minimums:
Front 22 kPa (0.22 kg/cm2, 3.2 psi)
Rear 22 kPa (0.22 kg/cm2, 3.2 psi)
3)Use no more than
Front 250 kPa (2.5 kg/cm2, 36 psi)
Rear 250 kPa (2.5 kg/cm2, 36 psi)
when seating the tire beads. Higher pres-
sures may cause the tire to burst.
Inflate the tires slowly and carefully.
Fast inflation could cause the tire to
burst.
● MAXIMUM LOADING LIMIT

1)Vehicle load limit (total weight of cargo,
rider and accessories, and tongue
weight): 210 kg (463 lb)
2)Front carrier : 40 kg (88 lb)
3)Rear carrier : 80 kg (176 lb)
4)Storage box: 2.0 kg (4.4 lb)
5)Trailer hitch:
3 - 50

INSP
TIRE INSPECTION ADJ
Pulling load (total weight of trailer and
cargo): 500 kg (1,102 lb)
Tongue weight (vertical weight on trailer
hitch point): 15 kg (33 lb)
Be extra careful of the machine balance and
stability when towing a trailer.
1.Measure:
● Tire pressure (cold tire pressure)

NOTE:
● The low-pressure tire gauge 1 is included
as standard equipment.
● If dust or the like is stuck to this gauge, it
will not provide the correct readings.

Therefore, take two measurements of the
tire’s pressure and use the second reading.
Cold tire
Front Rear
pressure
25 kPa 25 kPa
Standard (0.25 kg/cm2, (0.25 kg/cm2,
3.6 psi) 3.6 psi)
22 kPa 22 kPa
Minimum (0.22 kg/cm2, (0.22 kg/cm2,
3.2 psi) 3.2 psi)
28 kPa 28 kPa
Maximum (0.28 kg/cm2, (0.28 kg/cm2,
4.0 psi) 4.0 psi)
WARNING
Uneven or improper tire pressure may
adversely affect the handling of this
machine and may cause loss of control.
● Maintain proper tire pressures.
● Set tire pressures when the tires are cold.
● Tire pressures must be equal in both front
tires and equal in both rear tires.

2.Inspect:
● Tire surfaces
Tire wear limit a:
Front and rear: 3.0 mm (0.12 in)
WARNING
It is dangerous to ride with a worn-out tire.
When tire wear is out of specification,
replace the tire immediately.
3 - 51

WHEEL INSPECTION/ INSP
CABLE INSPECTION AND LUBRICATION ADJ
WHEEL INSPECTION
1.Inspect:
● Wheels 1
Damage/bends → Replace.
NOTE:
Always balance the wheel when a tire or
wheel has been changed or replaced.
WARNING
● Never attempt even small repairs to the
wheel.
● Ride conservatively after installing a tire
to allow it to seat itself properly on the
rim.
CABLE INSPECTION AND LUBRICATION
WARNING
A damaged cable sheath may cause corro-
sion and interfere with the cable move-
ment. An unsafe condition may result so
replace a damaged cable as soon as possi-
ble.
1.Inspect:
● Cable sheath
Damage → Replace.
2.Check:
● Cable operation
Unsmooth operation → Lubricate or

replace.
Recommended lubricant:
Yamaha chain and cable lube or
Engine oil
NOTE:
Hold the cable end up and apply several
drops of lubricant to the cable.
3.Apply:
● Lithium soap base grease
(onto end of the cable)
3 - 52

INSP
LEVERS, PEDAL, ETC. LUBRICATION ADJ
LEVERS, PEDAL, ETC. LUBRICATION
1.Lubricate the pivoting parts.
Recommended lubricant:
Yamaha chain and cable lube or
Engine oil
3 - 53

INSP
BATTERY INSPECTION ADJ
EB305000
ELECTRICAL
BATTERY INSPECTION
NOTE:
Since the MF battery is a sealed type bat-
tery, it is not possible to measure the spe-
cific gravity of the electrolyte in order to
check the charge state of the battery. There-
fore the charge of the battery has to be
checked by measuring the voltage at the
battery terminals.
CAUTION:
CHARGING METHOD
● This is a sealed type battery. Never
remove the sealing caps. If the sealing

caps have been removed, the balance will
not be maintained and battery perfor-
mance will deteriorate.
● Charging time, charging current and
charging voltage for the MF battery are
different from those of general type bat-
teries. The MF battery should be charged
as explained in “CHARGING METHOD”. If
the battery is overcharged, the electrolyte
level will drop considerably. Therefore,
take special care when charging the bat-
tery.
WARNING
Battery electrolyte is dangerous; it contains
sulfuric acid which is poisonous and highly
caustic.
Always follow these preventive measures:
● Avoid bodily contact with electrolyte as it
can cause severe burns or permanent eye

injury.
● Wear protective eye gear when handling
or working near batteries.

Antidote (EXTERNAL):
● SKIN - Wash with water.
● EYES - Flush with water for 15 minutes
and get immediate medical attention.

Antidote (INTERNAL):
● Drink large quantities of water or milk fol-
lowed with milk of magnesia, beaten egg

or vegetable oil. Get immediate medical
attention.
3 - 54

INSP
Batteries generate explosive hydrogen gas.
Always follow these preventive measures:
● Charge batteries in a well-ventilated area.
● Keep batteries away from fire, sparks or
open flames (e.g., welding equipment,

lighted cigarettes, etc.).
● DO NOT SMOKE when charging or han-
dling batteries.
KEEP BATTERIES AND ELECTROLYTE OUT
OF REACH OF CHILDREN.
1.Remove:
● Seat
● Battery holding bracket
● Battery lead cover

AND FUEL TANK”.
2.Disconnect:
● Battery leads
CAUTION:
First disconnect the negative lead 1, then
disconnect the positive lead 2.
3.Remove:
● Battery
4.Check:
● Battery condition
*********************************
Battery condition checking steps:
● Connect a digital voltmeter to the battery
terminals.
Tester (+) lead → battery (+) terminal
Tester (–) lead → battery (–) terminal
NOTE:
The charge state of an MF battery can be
checked by measuring the open-circuit volt-
age (i.e. the voltage when the positive ter-
minal is disconnected).
Open-circuit
Charging time
voltage
No charging is
12.8 V or higher
necessary.
3 - 55

INSP
● Check the condition of the battery using
the following charts.
Example:
● Open-circuit voltage = 12.0 V
● Charging time = 6.5 hours
● Charge condition of the battery = 20 ~ 30%
● Charging method for MF batteries
CAUTION:
● If it is impossible to set the standard
charging current, be careful not to over-
charge.
● When charging the battery, be sure to
remove it from the motorcycle. (If charg-
ing has to be done with the battery
mounted on the motorcycle, be sure to
disconnect the wire at the negative termi-
nal.)
● Never remove the sealing caps of an MF
battery.
● Make sure that the charging clips are in
full contact with the terminal and that
they are not shorted together. (A cor-
roded clip on the charger may cause the
battery to generate heat in the contact
area. A weak clip spring may cause
sparks.)
● Before removing the clips from the bat-
tery terminals, be sure to turn off the
charger’s power switch.
● The open-circuit voltage variation for the
MF battery, after charging, is shown
below. As shown in the figure, the open-
circuit voltage stabilizes about 30 min-
utes after charging has been completed.
Therefore, wait 30 minutes after charging
is completed before measuring the open-
circuit voltage.
3 - 56

INSP
Charging method using a variable voltage charger
3 - 57

INSP
Charging method using a constant voltage charger
3 - 58

INSP
BATTERY INSPECTION/FUSE INSPECTION ADJ
5.Inspect:
● Battery terminals
Dirty → Clean with a wire brush.

Poor connection → Correct.
NOTE:
After cleaning the terminals, apply a light
coat of grease.
6.Install:
● Battery
7.Connect:
● Battery leads
CAUTION:
First, connect the positive lead 1, then
connect the negative lead 2.
8.Install:
● Battery lead cover
● Battery holding bracket
● Seat

AND FUEL TANK”.
FUSE INSPECTION
CAUTION:
Always turn off the main switch when
checking or replacing a fuse. Otherwise, a
short circuit may occur.
1.Remove:
● Seat

AND FUEL TANK”.
2.Inspect:
● Fuses
*********************************
Inspection steps:
● Connect the pocket tester to the fuse and
check it for continuity.
3 - 59

INSP
FUSE INSPECTION ADJ
NOTE:
Set the tester to the “Ω × 1” position.
Pocket tester:
P/N. YU-03112, 90890-03112
● If the tester indicates o, replace the fuse.

*********************************
3.Replace:
● Blown fuse
*********************************
Replacement steps:
● Turn off the ignition.
● Install a new fuse of the proper amperage.
● Turn on switches to verify operation of
the related electrical devices.
● If the fuse immediately blows again, check
the electrical circuit.
*********************************
Description Current rating Quantity
Main 30 A 1
Headlight 15 A 1
Ignition 10 A 1
Signal 10 A 1
Terminal
(Auxiliary DC 10 A 1
jack)
4WD (Four-
3A 1
wheel drive)
Reserve 30 A 1
Reserve 15 A 1
Reserve 10 A 1
Reserve 3A 1
WARNING
Never use a fuse with a rating other than
that specified. Never use other materials in
place of a fuse. An improper fuse may
cause extensive damage to the electrical
system, a malfunction of the lighting and
ignition systems and could possibly cause
a fire.
4.Install:
● Seat

3 - 60 AND FUEL TANK”.

HEADLIGHT BEAM ADJUSTMENT/ INSP
HEADLIGHT BULB REPLACEMENT ADJ
HEADLIGHT BEAM ADJUSTMENT
1.Adjust:
● Headlight beam (vertically)
Turn the adjuster 1 in or out.
Turning in Headlight beam raised.

Turning out Headlight beam lowered.
HEADLIGHT BULB REPLACEMENT

1.Remove:
● Front carrier

AND FUEL TANK”.
2.Disconnect:
● Headlight lead couplers 1
3.Remove:
● Cover 1
4.Remove:
● Cover 1
● Bulb holder 2
● Bulb
NOTE:
Turn the bulb holder counterclockwise and
remove the defective bulb.
WARNING
Keep flammable products and your hands
away from the bulb while it is on, since it
will be hot. Do not touch the bulb until it
cools down.
3 - 61

INSP
HEADLIGHT BULB REPLACEMENT ADJ
5.Install:
● Bulb New
Secure the new bulb with the headlight
unit.
CAUTION:
Avoid touching the glass part of the bulb.
Keep it free from oil; otherwise, the trans-
parency of the glass, life of the bulb, and
luminous flux will be adversely affected. If
oil gets on the bulb, thoroughly clean it
with a cloth moistened with alcohol or lac-
quer thinner.
6.Install:
● Bulb holder
● Cover
7.Connect:
● Headlight lead couplers
8.Install:
● Front carrier

AND FUEL TANK”.
3 - 62

ENG
4
ENG
CHAPTER 4.
ENGINE
ENGINE REMOVAL ......................................................................................4-1

AIR DUCTS, MUFFLER AND EXHAUST PIPE .....................................4-1
SELECT LEVER UNIT AND COOLANT RESERVOIR ...........................4-2
HOSES AND LEADS .............................................................................4-3
ENGINE MOUNTING BOLTS ...............................................................4-4
ENGINE INSTALLATION ......................................................................4-6
CYLINDER HEAD ..........................................................................................4-7

CYLINDER HEAD REMOVAL ................................................................4-9
TAPPET COVER INSPECTION ............................................................4-10
TIMING CHAIN TENSIONER INSPECTION .......................................4-10
CAMSHAFT SPROCKET INSPECTION ..............................................4-10
CYLINDER HEAD INSPECTION ..........................................................4-11
CYLINDER HEAD INSTALLATION .....................................................4-12
CAMSHAFT, ROCKER ARMS AND VALVES ............................................4-15

CAMSHAFT AND ROCKER ARM REMOVAL ....................................4-17
VALVE AND VALVE SPRING REMOVAL ...........................................4-17
CAMSHAFT INSPECTION ..................................................................4-18
ROCKER ARM AND CAMSHAFT INSPECTION ................................4-18
VALVE AND VALVE SPRING INSPECTION .......................................4-19
VALVE AND VALVE SPRING INSTALLATION ..................................4-24
CAMSHAFT AND ROCKER ARM INSTALLATION ............................4-25
CYLINDER AND PISTON ............................................................................4-26

PISTON REMOVAL .............................................................................4-27
TIMING CHAIN GUIDE INSPECTION ................................................4-27
CYLINDER AND PISTON INSPECTION .............................................4-27
PISTON RING INSPECTION ...............................................................4-29
PISTON PIN INSPECTION ..................................................................4-30
PISTON INSTALLATION ....................................................................4-31
CYLINDER INSTALLATION ................................................................4-32
RECOIL STARTER AND CDI MAGNETO ...................................................4-33

CDI MAGNETO REMOVAL .................................................................4-36
RECOIL STARTER DISASSEMBLY ....................................................4-36
CDI MAGNETO INSPECTION .............................................................4-36
STARTER CLUTCH INSPECTION .......................................................4-37
STARTER PULLEY INSPECTION .......................................................4-38
RECOIL STARTER INSPECTION ........................................................4-38
RECOIL STARTER ASSEMBLY ..........................................................4-38
CDI MAGNETO INSTALLATION ........................................................4-39

ENG
PRIMARY AND SECONDARY SHEAVES ..................................................4-42
PRIMARY SHEAVE .............................................................................4-44
SECONDARY SHEAVE .......................................................................4-45
PRIMARY AND SECONDARY SHEAVES REMOVAL ........................4-46
SECONDARY SHEAVE DISASSEMBLY ............................................4-46
PRIMARY SHEAVE INSPECTION .......................................................4-47
SECONDARY SHEAVE INSPECTION ................................................4-47
PRIMARY SHEAVE ASSEMBLY .........................................................4-48
SECONDARY SHEAVE ASSEMBLY ..................................................4-48
PRIMARY AND SECONDARY SHEAVES INSTALLATION ...............4-50
CLUTCH .......................................................................................................4-51
CLUTCH REMOVAL ............................................................................4-53
CLUTCH INSPECTION ........................................................................4-53
CLUTCH INSTALLATION ...................................................................4-54
CRANKCASE ...............................................................................................4-56
STARTER MOTOR, TIMING CHAIN AND OIL FILTER ......................4-56
CRANKCASE .......................................................................................4-58
CRANKCASE BEARING ......................................................................4-59
OIL PUMP DRIVE GEAR REMOVAL ..................................................4-60
CRANKCASE SEPARATION ...............................................................4-60
TIMING CHAIN AND GUIDE INSPECTION .......................................4-61
OIL STRAINER AND OIL DELIVERY PIPE INSPECTION ...................4-61
CRANKCASE INSPECTION ................................................................4-62
BEARINGS AND OIL SEALS INSPECTION .......................................4-62
CRANKCASE ASSEMBLY ..................................................................4-62
SHIFT LEVER INSTALLATION ...........................................................4-63
OIL PUMP DRIVE GEAR INSTALLATION ..........................................4-64
CRANKSHAFT AND OIL PUMP .................................................................4-65

OIL PUMP ............................................................................................4-66
CRANKSHAFT REMOVAL ..................................................................4-67
OIL PUMP INSPECTION .....................................................................4-67
CRANKSHAFT INSPECTION ..............................................................4-68
CRANKSHAFT AND BALANCER INSTALLATION ............................4-69
TRANSMISSION .........................................................................................4-70
SHIFT FORK INSPECTION ..................................................................4-72
SHIFT CAM INSPECTION ...................................................................4-72
TRANSMISSION INSPECTION ..........................................................4-73
TRANSMISSION INSTALLATION ......................................................4-73

ENG
MIDDLE GEAR ............................................................................................4-75
MIDDLE DRIVE SHAFT .......................................................................4-75
MIDDLE DRIVEN SHAFT ....................................................................4-76
MIDDLE DRIVE SHAFT REMOVAL ....................................................4-78
MIDDLE DRIVEN SHAFT REMOVAL .................................................4-78
INSPECTION .......................................................................................4-80
MIDDLE DRIVE AND DRIVEN GEAR SHIM SELECTION ..................4-81
MIDDLE DRIVEN SHAFT INSTALLATION .........................................4-84
MIDDLE DRIVE SHAFT INSTALLATION ............................................4-86
GEAR LASH MEASUREMENT ...........................................................4-86

ENG

ENGINE REMOVAL ENG
ENGINE
ENGINE REMOVAL
AIR DUCTS, MUFFLER AND EXHAUST PIPE

Air ducts, muffler and exhaust pipe Remove the parts in the order below.
removal
Engine oil Refer to “ENGINE OIL REPLACEMENT”
in CHAPTER 3.
Front and rear fender/footrest
boards Refer to “SEAT, CARRIERS, FENDERS
AND FUEL TANK” in CHAPTER 3.
Fuel tank/rubber cover
Carburetor assembly Refer to “CARBURETOR” in CHAPTER 6.
1 Air duct assembly 1 1
2 Muffler 1
3 Exhaust pipe stay 1 1
4 Exhaust pipe/gasket 1/1
5 Air duct assembly 2 1
procedure.
4-1

ENGINE REMOVAL ENG
SELECT LEVER UNIT AND COOLANT RESERVOIR

Select lever unit and coolant Remove the parts in the order below.
reservoir removal
1 Shift arm 1
2 Select lever shift rod 1
3 Select lever unit 1
4 Coolant reservoir breather hose 1
5 Coolant reservoir hose 1
6 Coolant reservoir 1
procedure.
4-2

ENGINE REMOVAL ENG
HOSES AND LEADS

Hoses and leads removal Remove the parts in the order below.
Water pump inlet hose Refer to “WATER PUMP” in CHAPTER 5.
2 Spark plug lead 1
3 Thermo switch lead 1
4 Starter motor lead 1
5 CDI magneto lead coupler 2
6 Speed sensor lead coupler 1
7 Neutral switch lead 1 Sky blue
8 Parking switch lead 1 Blue/Red
9 Reverse switch lead 1 Green/Blue
10 Engine ground lead 1
11 Speedometer gear unit 1
procedure.
4-3

ENGINE REMOVAL ENG
ENGINE MOUNTING BOLTS

Engine mounting bolt removal Remove the parts in the order below.
Rear wheels Refer to “FRONT AND REAR WHEELS”
in CHAPTER 8.
Swingarm Refer to “REAR SHOCK ABSORBER
AND SWINGARM” in CHAPTER 8.
1 Engine mounting bolt (rear-lower)/ 1/1
nut
2 Engine mounting bolt (rear-upper)/ 1/1
nut CAUTION:
3 Engine bracket bolt (front-lower) 4 Install all of the bolts/nuts and then
4 Engine mounting bolt (font-lower) 2 tighten them to full torque specifica-
5 Engine bracket (front-lower) 2 tions.
6 Engine bracket bolt (front-upper) 2 Refer to “ENGINE INSTALLATION”.
7 Engine mounting bolt (front-upper)/ 1/1
nut
8 Engine bracket (front-upper) 1
4-4

ENGINE REMOVAL ENG

9 Engine assembly 1 NOTE:
Remove the engine assembly from the
left side of the machine.
procedure.
4-5

ENGINE REMOVAL ENG
ENGINE INSTALLATION
1.Install:
● Engine bracket (front upper) 1
● Engine mount bolt (front upper)/nut 2
● Engine bracket bolt (front upper) 3
● Engine bracket (front lower) 4
● Engine mount bolt (front lower) 5
● Engine bracket bolt (front lower) 6
● Engine mount bolt (rear upper)/nut 7
● Engine mount bolt (rear lower)/nut 8
NOTE:
Do not fully tighten the bolts and nuts.
2.Tighten:
● Engine mount bolt (front upper)/nut 2
42 Nm (4.2 m • kg, 30 ft • lb)
T.
R.
● Engine bracket bolt (front upper) 3
33 Nm (3.3 m • kg, 24 ft • lb)
T.
R.
● Engine mount bolt (front lower) 5
42 Nm (4.2 m • kg, 30 ft • lb)
T.
R.
● Engine bracket bolt (front lower) 6
33 Nm (3.3 m • kg, 24 ft • lb)
T.
R.
● Engine mount bolt (rear upper)/nut 7
56 Nm (5.6 m • kg, 40 ft • lb)
T.
R.
● Engine mount bolt (rear lower)/nut 8
56 Nm (5.6 m • kg, 40 ft • lb)
T.
R.
4-6

CYLINDER HEAD ENG
CYLINDER HEAD

Cylinder head removal Remove the parts in the order below.
Fuel tank/rubber cover Refer to “SEAT, CARRIERS, FENDERS
Front fender/air filter case AND FUEL TANK” in CHAPTER 3.
Air duct assembly 1
Refer to “ENGINE REMOVAL”.
Exhaust pipe/muffler
Carburetor assembly Refer to “CARBURETOR” in CHAPTER 6.
Recoil starter/timing plug Refer to “VALVE CLEARANCE ADJUST-
MENT” in CHAPTER 3.
Thermostat Refer to “THERMOSTAT” in CHAPTER 5.
1 Spark plug lead 1
2 Spark plug 1
3 Engine mount bolt (upper)/nut 1/1
4 Engine bracket (upper) 1
4-7

CYLINDER HEAD ENG

6 Camshaft sprocket cover/O-ring 1/1
7 Tappet cover/O-ring 2/2
8 Thermo switch lead 1 Disconnect.
9 Timing chain tensioner cap bolt 1
10 Timing chain tensioner/gasket 1/1 Refer to “CYLINDER HEAD REMOVAL/
11 Camshaft sprocket 1 INSTALLATION”.
12 Cylinder head 1
13 Cylinder head gasket 1
14 Dowel pin 2
15 O-ring 1
procedure.
4-8

CYLINDER HEAD ENG
CYLINDER HEAD REMOVAL
1.Align:
● “T” mark
(with stationary pointer)

*********************************
Checking steps:
a wrench.
NOTE:
● When the piston is at the Top Dead Center
(T.D.C.) on the compression stroke, there

should be clearance between the valve
stem tips and their respective rocker arm
adjusting screws.
● If there is no clearance, rotate the crank-
shaft counterclockwise one turn.
*********************************
2.Loosen:
● Camshaft sprocket bolt 1
NOTE:
Use the rotor holder 2 to hold the starter
pulley.
Rotor holder:
P/N. YU-01235, 90890-01235
3.Loosen:
● Timing chain tensioner cap bolt
4.Remove:
● Timing chain tensioner
● Camshaft sprocket
4-9

CYLINDER HEAD ENG
NOTE:
● Fasten a safety wire to the timing chain to
prevent it from falling into the crankcase.

● When removing the camshaft sprocket, it
is not necessary to separate the timing

chain.
5.Remove:
● Cylinder head
NOTE:
● Loosen the 6 mm bolts first.
● Working in a crisscross pattern, loosen
each 10 mm bolt 1/4 of a turn. After all the

bolts are loosened, remove them.
TAPPET COVER INSPECTION

1.Inspect:
● Tappet covers 1
● O-rings 2
Cracks/damage → Replace.
TIMING CHAIN TENSIONER INSPECTION

1.Check:
● One-way cam operation (tensioner)
Unsmooth operation → Replace.
CAMSHAFT SPROCKET INSPECTION

1.Inspect:
Wear/damage → Replace the camshaft

sprocket and timing chain as a set.
a 1/4 of a tooth
b Correct
1 Timing chain
2 Sprocket
4 - 10

CYLINDER HEAD ENG
CYLINDER HEAD INSPECTION
1.Eliminate:
● Carbon deposits (from the combustion
chambers)
Use a rounded scraper.
NOTE:
Do not use a sharp instrument to avoid
damaging or scratching:
● Spark plug threads
● Valve seats
2.Inspect:
● Cylinder head
Scratches/damage → Replace.
● Cylinder head water jacket
Mineral deposits/rust → Eliminate.
3.Measure:
● Cylinder head warpage
Out of specification → Resurface.
Cylinder head warpage:

Less than 0.03 mm (0.0012 in)
*********************************
Warpage measurement and resurfacement
steps:
● Place a straightedge and a feeler gauge
across the cylinder head.
● Use a feeler gauge to measure the
warpage.
● If the warpage is out of specification,
resurface the cylinder head.
● Place a 400 ~ 600 grit wet sandpaper on
the surface plate, and resurface the head
using a figure-eight sanding pattern.
NOTE:
To ensure an even surface rotate the cylin-
der head several times.
*********************************
4 - 11

CYLINDER HEAD ENG
CYLINDER HEAD INSTALLATION
1.Install:
● Cylinder head
● Bolt (M10) 40 Nm (4.0 m • kg, 29 ft • lb)
T.
R.
● Bolt (M6) 10 Nm (1.0 m • kg, 7.2 ft • lb)
T.
R.
NOTE:
● Lubricate the washer with engine oil.
● Tighten the bolts (M10) in two stages and
a crisscross pattern.
2.Install:
*********************************
Installing steps:
● Rotate the camshaft to align the camshaft
pin 1 with the cylinder head match mark
2.
a wrench.
CAUTION:
Do not turn the crankshaft during the cam-
shaft sprocket installation.
● Place the timing chain onto the camshaft
sprocket.
● Install the camshaft sprocket onto the
camshaft and finger tighten the sprocket
bolt.
4 - 12

CYLINDER HEAD ENG
NOTE:
Be sure the punch mark 5 on the camshaft
sprocket is aligned with the match mark 2
on the cylinder head.
● Force the camshaft clockwise and coun-
terclockwise to remove timing chain slack.
● Insert a screwdriver into the timing chain
tensioner hole and push the timing chain
guide inward.
● While pushing the timing chain guide, be
sure that the camshaft sprocket punch
mark 5 is aligned with the cylinder head
match mark 2.
● If the marks are aligned, tighten the cam-
shaft sprocket bolt. If the marks are not
aligned, change the meshing position of
the camshaft sprocket and timing chain.
*********************************
3.Install:
● Timing chain tensioner
*********************************
Installation steps:
● Remove the tensioner cap bolt 1, washer
2 and spring 3.
● Release the timing chain tensioner one-
way cam 4 and push the tensioner rod 5
all the way in.
● Install the tensioner 6 with a new gasket
into the cylinder.
Bolts (timing chain tensioner):

11 Nm (1.1 m • kg, 8.0 ft • lb)
T.
R.
WARNING
Always use a new gasket.
● Install the spring, washer and cap bolt.
Cap bolt (timing chain tensioner):

23 Nm (2.3 m • kg, 17 ft • lb)
T.
R.
*********************************
4 - 13

CYLINDER HEAD ENG
4.Tighten:
● Camshaft sprocket bolt 1
60 Nm (6.0 m • kg, 43 ft • lb)
T.
R.
NOTE:
pulley.
Rotor holder:
P/N. YU-01235, 90890-01235
5.Check:
● Camshaft sprocket punch mark
● Rotor “T” mark
Out of alignment → Adjust.
4 - 14

CAMSHAFT, ROCKER ARMS AND VALVES ENG
CAMSHAFT, ROCKER ARMS AND VALVES

Camshaft, rocker arms and valves Remove the parts in the order below.
removal
1 Intake manifold/O-ring 1/1
2 Thermo switch 1
3 Oil check bolt 1
4 Lock washer/bearing retainer 1/1
5 Camshaft 1
Refer to “CAMSHAFT AND ROCKER
6 Rocker arm shaft/O-ring 2/2
ARM REMOVAL/INSTALLATION”.
7 Rocker arm 2
8 Locknut/valve adjuster 2/2
9 Valve cotter 4
Refer to “VALVE AND VALVE SPRING
10 Valve spring retainer 2
REMOVAL/INSTALLATION”.
11 Valve spring (outer) 2
4 - 15


12 Valve spring (inner) 2
13 Valve (intake) 1
14 Valve (exhaust) 1
15 Valve stem seal 2
16 Valve spring seat 2
procedure.
4 - 16

CAMSHAFT AND ROCKER ARM REMOVAL
1.Remove:
● Camshaft 1
NOTE:
Screw in a M10 bolt 2 into the thread hole
on the camshaft, and pull out the camshaft.
2.Remove:
● Rocker arm shafts (intake and exhaust) 1
● Rocker arms 2
NOTE:
Use a slide hammer 3 to remove the rocker
arm shafts.
Slide hammer set:

P/N. YU-01083-A
Slide hammer bolt (M6):
P/N. 90890-01083
Weight:
P/N. 90890-01084
VALVE AND VALVE SPRING REMOVAL

1.Check:
● Valve sealing
Leakage at the valve seat → Inspect the

valve face, valve seat and valve seat
width.
INSPECTION”.
*********************************
Checking steps:
● Pour a clean solvent 1 into the intake and
exhaust ports.
● Check that the valve seals properly.
There should be no leakage at the valve
seat 2.
*********************************
4 - 17

2.Remove:
● Valve cotters
NOTE:
Attach a valve spring compressor 1
between the valve spring retainer and the
cylinder head to remove the valve cotters.
Valve spring compressor:

P/N. YM-04019, 90890-04019
CAMSHAFT INSPECTION
1.Inspect:
● Cam lobes
Pitting/scratches/blue discoloration →
Replace.
2.Measure:
● Cam lobes length a and b.
Camshaft lobe limit:

Intake:
a 40.52 mm (1.595 in)
b 32.08 mm (1.263 in)
Exhaust:
a 40.52 mm (1.595 in)
b 32.08 mm (1.263 in)
ROCKER ARM AND CAMSHAFT INSPECTION

1.Inspect:
● Camshaft bushings
Damage/wear → Replace.
2.Inspect:
● Camshaft lobes 1
● Valve adjusters 2
Blue discoloration/pitting/scratches →
Replace.
3.Inspect:
● Rocker arms
● Rocker arm shafts
*********************************
Inspection steps:
● Inspect the two contact areas on the
rocker arms for signs of abnormal wear.
1) Rocker arm shaft hole.
2) Camshaft lobe contact surface.
Excessive wear → Replace.
4 - 18

● Inspect the surface of the rocker arm shafts.
Blue discoloration/pitting/scratches →
Replace/check lubrication.
● Measure the inside diameter a of the
rocker arm holes.
Rocker arm inside diameter:

12.000 ~ 12.018 mm
(0.4724 ~ 0.4731 in)
● Measure the outside diameter b of the

rocker arm shafts.
Rocker arm outside diameter:

11.981 ~ 11.991 mm
(0.4717 ~ 0.4721 in)
● Calculatethe clearance by subtracting the

rocker arm shaft outside diameter from
the rocker arm inside diameter.
Clearance greater than 0.08 mm (0.003 in)
→ Replace the defective part(s).
Rocker arm to shaft standard

clearance:
0.009 ~ 0.037 mm
(0.0004 ~ 0.0015 in)
*********************************
VALVE AND VALVE SPRING INSPECTION

1.Measure:
● Stem-to-guide clearance
Stem-to-guide clearance =
valve guide inside diameter a –
valve stem diameter b
Out of specification → Replace the valve

guide.
Clearance (stem to guide):

Intake:
0.010 ~ 0.037 mm
(0.0004 ~ 0.0015 in)
<Limit>: 0.08 mm (0.003 in)
Exhaust:
0.030 ~ 0.057 mm
(0.0012 ~ 0.0022 in)
<Limit>: 0.10 mm (0.004 in)
4 - 19

2.Replace:
● Valve guide
*********************************
Replacement steps:
NOTE:
To ease guide removal, installation and to
maintain correct fit, heat the cylinder head
to 100 ˚C (212 ˚F) in an oven.
● Remove the valve guide using a valve
guide remover 1.
● Install the new valve guide using a valve
guide remover 1 and valve guide installer
2.
● After installing the valve guide, bore the
valve guide using a valve guide reamer 3
to obtain proper stem-to-guide clearance.
Valve guide remover (7 mm):

P/N. YM-01225-A, 90890-01225
Valve guide installer:
P/N. YM-04017, 90890-04017
Valve guide reamer (7 mm):
P/N. YM-01227, 90890-01227
NOTE:
After replacing the valve guide reface the
valve seat.
*********************************
3.Inspect:
● Valve face
Pitting/wear → Grind the face.

● Valve stem end
Mushroom shape or diameter larger than

the body of the stem → Replace.
4.Measure:
● Margin thickness a
Margin thickness:
Intake:
1.0 ~ 1.4 mm (0.0394 ~ 0.0551 in)
Exhaust:
0.8 ~ 1.2 mm (0.0315 ~ 0.0472 in)
4 - 20

5.Measure:
● Runout (valve stem)
Runout limit:
0.01 mm (0.0004 in)
NOTE:
● When installing a new valve always
replace the guide.
● If the valve is removed or replaced always
replace the oil seal.

6.Eliminate:
● Carbon deposits
(from the valve face and valve seat)

7.Inspect:
● Valve seats
Pitting/wear → Reface the valve seat.
8.Measure:
● Valve seat width a
Out of specification → Reface the valve

seat.
Valve seat width:

Intake:
1.2 ~ 1.4 mm (0.0472 ~ 0.0551 in)
<Limit>: 1.6 mm (0.0630 in)
Exhaust:
1.2 ~ 1.4 mm (0.0472 ~ 0.0551 in)
<Limit>: 1.6 mm (0.0630 in)
*********************************
Measurement steps:
● Apply Mechanic’s blueing dye (Dykem) b
to the valve face.
● Install the valve into the cylinder head.
● Press the valve through the valve guide
and onto the valve seat to make a clear
pattern.
● Measure the valve seat width. Where the
valve seat and valve face made contact,
blueing will have been removed.
● If the valve seat is too wide, too narrow,
or the seat is not centered, the valve seat
must be refaced.
*********************************
4 - 21

9.Lap:
● Valve face
● Valve seat
NOTE:
After refacing the valve seat or replacing
the valve and valve guide, the valve seat
and valve face should be lapped.
*********************************
Lapping steps:
● Apply a coarse lapping compound to the
valve face.
CAUTION:
Do not let the compound enter the gap
between the valve stem and the guide.
● Apply molybdenum disulfide oil to the
valve stem.
● Turn the valve until the valve face and
valve seat are evenly polished, then clean
off all of the compound.
NOTE:
For best lapping results, lightly tap the
valve seat while rotating the valve back and
forth between your hands.
● Apply a fine lapping compound to the
valve face and repeat the above steps.
NOTE:
After every lapping operation be sure to
clean off all of the compound from the
valve face and valve seat.
● Apply Mechanic’s blueing dye (Dykem) to
the valve face.
● Press the valve through the valve guide
and onto the valve seat to make a clear
pattern.
● Measure the valve seat width again. If the
valve seat width is out of specification,
reface and relap the valve seat.
*********************************
4 - 22

10.Measure:
● Valve spring free length a
Free length (valve spring):

Inner:
39.9 mm (1.57 in)
<Limit>: 37.9 mm (1.49 in)
Outer:
43.27 mm (1.71 in)
<Limit>: 41.27 mm (1.62 in)
11.Measure:
●Compressed spring force a
b Installed length
Compressed spring force:

Inner:
104.9 ~ 120.6 N at 33.6 mm
(10.70 ~ 12.30 kg,
23.58 ~ 27.11 lb at 1.32 in)
Outer:
235.4 ~ 251.1 N at 36.6 mm
(24.00 ~ 25.60 kg,
52.92 ~ 56.45 lb at 1.44 in)
12.Measure:
● Spring tilt a
Spring tilt limit:

Inner:
2.5˚/1.6 mm (0.06 in)
Outer:
2.5˚/1.6 mm (0.06 in)
4 - 23

VALVE AND VALVE SPRING
INSTALLATION
1.Apply:
● Molybdenum disulfide oil
(onto the valve stem and valve stem seal)

2.Install:
● Valve spring seats
● Valve stem seals New

● Valves
● Valve springs (inner and outer)
● Valve spring retainers
NOTE:
Install the valve springs with the larger
pitch a facing upwards.
b Smaller pitch
3.Install:
● Valve cotters
NOTE:
Install the valve cotters while compressing
the valve spring with the valve spring com-
pressor 1.
Valve spring compressor:

P/N. YM-04019, 90890-04019
4.To secure the valve cotters onto the valve

stem, lightly tap the valve tip with a piece
of wood.
CAUTION:
Hitting the valve tip with excessive force
could damage the valve.
4 - 24

CAMSHAFT AND ROCKER ARM
INSTALLATION
1.Apply:
● Engine oil
(onto the rocker arm shafts)

2.Install:
● Rocker arms 1
● Rocker arm shafts (intake and exhaust) 2
NOTE:
Use a slide hammer bolt 3 to install the
rocker arm shaft.
3.Install:
● Camshaft 1
NOTE:
Install the camshaft pin hole a facing up.
4 - 25

CYLINDER AND PISTON ENG
CYLINDER AND PISTON

Cylinder and piston removal Remove the parts in the order below.
Cylinder head Refer to “CYLINDER HEAD”.
Water pump outlet hose/pipe Refer to “WATER PUMP” in CHAPTER 5.
1 Cooling water inlet joint 1
2 Timing chain guide (exhaust) 1
3 Cylinder/O-ring 1/1 Refer to “CYLINDER INSTALLATION”.
4 Cylinder gasket 1
5 Dowel pin 2
6 O-ring 1
7 Piston pin clip 2
8 Piston pin 1 Refer to “PISTION REMOVAL/INSTAL-
9 Piston 1 LATION”.
10 Piston ring set 1
procedure.
4 - 26

PISTON REMOVAL
1.Remove:
● Piston pin clips 1
● Piston pin 2
● Piston 3
NOTE:
Before removing piston pin, deburr the clip
groove and pin hole area. If the piston pin
groove is deburred and the piston pin is still
difficult to remove, use the piston pin puller
4.
Piston pin puller:

P/N. YU-01304, 90890-01304
CAUTION:
Do not use a hammer to drive the piston
pin out.
2.Remove:
● Piston rings
NOTE:
Spread the end gaps apart while at the
same time lifting the piston ring over the
top of the piston crown.
TIMING CHAIN GUIDE INSPECTION

1.Inspect:
● Exhaust side timing chain guide
CYLINDER AND PISTON INSPECTION

1.Inspect:
● Cylinder and piston walls
Vertical scratches → Rebore or replace the

cylinder and the piston.
● Cylinder water jacket
Mineral deposits/rust → Eliminate.
4 - 27

2.Measure:
● Piston-to-cylinder clearance
*********************************
Measurement steps:
1st step:
● Measure the cylinder bore “C” with the
cylinder bore gauge.
NOTE:
Measure cylinder bore “C” by taking side-
to-side and front-to-back measurements of
the cylinder. Then, find the average of the
measurements.
84.500 ~ 84.510 mm
Cylinder bore “C”
(3.3268 ~ 3.3272 in)
0.05 mm
Max. taper “T”
(0.0016 in)
0.01 mm
Out of round “R”
(0.0004 in)
“C”= maximum of D1 ~ D6
“T”= maximum of D1, or D2 –
maximum of D5 or D6
“R”= maximum of D1, D3 or D5 –
minimum of D2, D4 or D6
● Ifout of specification, replace the cylinder,

and the pistons and piston rings as a set.
2nd step:
● Measure piston skirt diameter “P” with a
micrometer.
a 5.0 mm (0.20 in) from the piston bottom edge
Piston skirt diameter “P”
84.445 ~ 84.460 mm
Standard
(3.3246 ~ 3.3252 in)
● Ifout of specification, replace the piston

and piston rings as a set.
4 - 28

3rd step:
● Find the piston-to-cylinder clearance with
the following formula.
Piston-to-cylinder clearance =
Cylinder bore “C” –
Piston skirt diameter “P”
Piston-to-cylinder clearance:
0.040 ~ 0.065 mm
(0.0016 ~ 0.0026 in)
<Limit>: 0.15 mm (0.0059 in)
● Ifout of specification, rebore or replace

the cylinder, and replace the piston and
piston rings as a set.
*********************************
PISTON RING INSPECTION

1.Measure:
● Ring side clearance
Use a feeler gauge.

Out of specification → Replace the piston
and rings as a set.
NOTE:
Clean carbon from the piston ring grooves
and rings before measuring the side clear-
ance.
Side clearance
Standard Limit
Top 0.03 ~ 0.08 mm 0.13 mm
ring (0.001 ~ 0.003 in) (0.005 in)
2nd 0.03 ~ 0.07 mm 0.13 mm

ring (0.001 ~ 0.003 in) (0.005 in)
2.Position:
● Piston ring
(in cylinder)
NOTE:
Insert a ring into the cylinder and push it
approximately 40 mm (1.6 in) into the cylin-
der. Push the ring with the piston crown so
that the ring will be at a right angle to the
cylinder bore.
a 40 mm (1.6 in)
4 - 29

3.Measure:
● Ring end gap

NOTE:
You cannot measure the end gap on the
expander spacer of the oil control ring. If
the oil control ring rails show excessive
gap, replace all three rings.
End gap
Standard Limit
Top 0.2 ~ 0.4 mm 0.65 mm
ring (0.008 ~ 0.016 in) (0.026 in)
2nd 0.4 ~ 0.6 mm 0.95 mm
ring (0.016 ~ 0.024 in) (0.037 in)
Oil 0.2 ~ 0.7 mm —
ring (0.008 ~ 0.028 in)
PISTON PIN INSPECTION

1.Inspect:
● Piston pin
Blue discoloration/grooves → Replace,

then inspect the lubrication system.
2.Measure:
● Piston pin-to-piston clearance
*********************************
Measurement steps:
● Measure the piston pin outside diameter
a.
If out of specification, replace the piston
pin.
Outside diameter (piston pin):

19.993 ~ 20.000 mm
(0.7871 ~ 0.7874 in)
● Measure the piston inside diameter b.

● Calculatethe piston pin-to-piston clear-
ance with the following formula.
Piston pin-to-piston clearance =

Bore size (piston pin) b –
Outside diameter (piston pin) a
4 - 30

● If out of specification, replace the piston.
Piston pin-to-piston clearance:

0.004 ~ 0.022 mm
(0.00016 ~ 0.00087 in)
<Limit>: 0.07 mm (0.003 in)
*********************************
PISTON INSTALLATION
1.Install:
● Piston rings
(onto the piston)

NOTE:
● Be sure to install the piston rings so that
the manufacturer’s marks or numbers are

located on the upper side of the rings.
● Lubricate the piston and piston rings liber-
ally with engine oil.
2.Position:
● Top ring
● 2nd ring
● Oil ring
Offset the piston ring end gaps as shown.

a Top ring end
b Oil ring end (upper)
c Oil ring end (lower)
d 2nd ring end
3.Install:
● Piston 1
● Piston pin 2
● Piston pin clips 3 New
NOTE:
● Apply engine oil onto the piston pin, pis-
ton ring and piston.

● Be sure that the arrow mark a on the pis-
ton points to the exhaust side of the

engine.
● Before installing the piston pin clip, cover
the crankcase with a clean rag to prevent

the piston pin clip from falling into the
crankcase.
4 - 31

4.Lubricate:
● Piston
● Piston rings
● Cylinder
NOTE:
Apply a liberal coating of engine oil.
CYLINDER INSTALLATION
1.Install:
● Cylinder
NOTE:
Install the cylinder with one hand while
compressing the piston rings with the other
hand.
CAUTION:
● Be careful not to damage the timing chain
damper during installation.
● Pass the timing chain through the timing
chain cavity.
4 - 32

RECOIL STARTER AND CDI MAGNETO ENG
RECOIL STARTER AND CDI MAGNETO

CDI magneto removal Remove the parts in the order below.
Engine oil Drain.
Refer to “ENGINE OIL REPLACEMENT”
in CHAPTER 3.
Seat and side panels Refer to “SEAT AND SIDE PANELS” in
CHAPTER 3.
Left footrest board Refer to “FOOTREST BOARDS” in
CHAPTER 3.
1 Recoil starter assembly 1
2 CDI magneto coupler 2 Disconnect.
3 Starter pulley 1
Refer to “CDI MAGNETO REMOVAL/
4 Crankcase cover (left)/gasket 1/1
INSTALLATION”.
5 Dowel pin 2
6 Lead holder 1
4 - 33


7 Pickup coil 1
8 Stator assembly 1
9 CDI rotor 1
Refer to “CDI MAGNETO REMOVAL/
10 Starter wheel gear 1
INSTALLATION”.
11 Woodruff key 1
12 Bearing/washer 1/1
13 Starter idle gear shaft 1
14 Washer/bearing 1/1
15 Starter idle gear 1
procedure.
4 - 34


Recoil starter disassembly Disassemble the parts in the order
below.
1 Cap 1
2 Starter handle 1
3 Friction plate 1
4 Pawl spring 1
Refer to “RECOIL STARTER DISAS-
5 Drive pawl 1
SEMBLY/ASSEMBLY”.
6 Spring 1
7 Sheave drum 1
8 Rope 1
9 Coil spring 1
For assembly, reverse the disassembly
procedure.
4 - 35

CDI MAGNETO REMOVAL
1.Remove:
● Starter pulley 1
NOTE:
pulley.
Rotor holder:
P/N. YU-01235, 90890-01235
2.Remove:
● Crankcase cover (left)
● Gasket
● Dowel pins
NOTE:
Working in a crisscross pattern, loosen each
bolt 1/4 of a turn. Remove them after all of
them are loosened.
3.Remove:
● CDI rotor 1
NOTE:
Use the flywheel puller 2.
Flywheel puller:
P/N. YM-01404, 90890-01404
RECOIL STARTER DISASSEMBLY

1.Remove:
● Cap 1
● Starter handle 2
NOTE:
Before untying the knot 3 above the starter
handle, make a knot 4 in the rope so that
the rope is not pulled into the case.
CDI MAGNETO INSPECTION

1.Inspect:
● Starter coil
● Pickup coil
Damage → Replace.
4 - 36

STARTER CLUTCH INSPECTION
1.Inspect:
● Starter one-way clutch 1
● Bolts 2 (starter clutch)
Loose → Replace with a new one, and

clinch the end of the bolt.
NOTE:
The arrow mark on the starter clutch must
face inward, away from the CDI rotor.
Bolts (starter clutch):

30 Nm (3.0 m • kg, 22 ft • lb)
LOCTITE®
*********************************
Inspection steps:
● Install the starter wheel gear to the starter
clutch, and hold the starter clutch.
● When turning the starter wheel gear
counter clockwise Å, the starter clutch
and the wheel gear should be engaged.
If not, the starter clutch is faulty. Replace it.
● When turning the starter wheel gear
clockwise ı, the starter wheel gear
should turn freely.
If not, the starter clutch is faulty. Replace it.
*********************************
2.Inspect:
● Gear teeth (starter idle) 1
● Gear teeth (starter wheel) 2
Burrs/clips/roughness/wear → Replace.
3.Inspect:
● Starter wheel gear
(contacting surface)
Damage/pitting/wear → Replace.
4 - 37

STARTER PULLEY INSPECTION
1.Inspect:
● Starter pulley
Cracks/pitting → Deburr or replace.
RECOIL STARTER INSPECTION

1.Inspect:
● Rope 1
● Sheave drum 2
● Drive pawl 3
● Coil spring 4
● Pawl spring 5
● Spring 6
Fatigue → Replace.
RECOIL STARTER ASSEMBLY

1.Install:
● Sheave drum 1
● Rope 2
● Pawl spring 3
● Drive pawl 4
NOTE:
Wind the rope 4-1/2 turns clockwise around
the sheave drum. Then insert the rope into
the drum slit a.
4 - 38

2.Install:
● Starter spring 1
● Sheave drum assembly 2
NOTE:
● Mesh the spring hook 3 with the case slit,
then wind the spring clockwise into the

case from the larger to smaller diameter.
● Mesh the sheave drum hook 4 with the
spring hook 5.
3.Install:
● Spring 1
● Friction plate 2
● Nut
NOTE:
Insert the spring hooks into the pawl side
holes.
4.Turn the sheave drum 3-turn clockwise to

give preload to the spring.
5.Install:
● Starter handle 1
● Cap 2
NOTE:
● Pass the rope through the case hole and
make a knot 3 on the rope so that the

rope is not pulled into the case.
● Untie the knot 3 after making a knot 4
above the handle.
CDI MAGNETO INSTALLATION

1.Apply:
®
● Sealant (Quick Gasket ) 1
(into the slit)
Sealant (Quick Gasket®):

P/N. ACC-11001-05-01
Yamaha bond No. 1215®:
P/N. 90890-85505
4 - 39

2.Install:
● Woodruff key
● CDI rotor
NOTE:
● Before installing the rotor, clean the out-
side of the crankshaft and the inside of the

rotor.
● After installing the rotor, check that the
rotor rotates smoothly. If not, reinstall the

key and rotor.
3.Install:
● Dowel pins
● Gasket New
● Crankcase cover (left)
10 Nm (1.0 m • kg, 7.2 ft • lb)
T.
R.
NOTE:
● When installing the crankcase cover (left),
use a long rod to hold the CDI rotor in

position from the outside. This will make
assembly easier. Be careful not to damage
the oil seal.
● Tighten the bolts in stages, using a criss-
cross pattern.
4.Install:
● Starter pulley 1
50 Nm (5.0 m • kg, 36 ft • lb)

T.
R.
NOTE:
Use a rotor holder 2 to hold the starter pul-
ley.
Rotor holder:
P/N. YU-01235, 90890-01235
NOTE:
Before installing the starter pulley, do not
forget to install the O-ring.
4 - 40

5.Install:
● Select lever unit
NOTE:
Before installing the select lever shift rod,
make sure that the select lever and shift
cam is in the NEUTRAL position.
6.Adjust:
Refer to “SELECT LEVER CONTROL

CABLE AND SHIFT ROD” in CHAPTER 3.
4 - 41

PRIMARY AND SECONDARY SHEAVES ENG
PRIMARY AND SECONDARY SHEAVES

Primary and secondary sheave Remove the parts in the order below.
removal
Front fender
Rear fender
Right footrest boards
3 Drive belt cover 1
4 Rubber gasket 1
5 Bearing housing 1
6 Dowel pin 2
7 Primary sheave assembly 1 Refer to “PRIMARY AND SECONDARY
8 V-belt 1 SHEAVES REMOVAL/INSTALLATION”.
4 - 42


9 Primary fixed sheave 1 Refer to “PRIMARY AND SECONDARY
10 Secondary sheave assembly 1 SHEAVES REMOVAL/INSTALLATION”.
procedure.
4 - 43

PRIMARY SHEAVE

Primary sheave disassembly Disassemble the parts in the order below.
1 Primary pulley sheave cap 1
2 Primary pulley slider 4
3 Spacer 4
4 Primary pulley cam 1
Refer to “PRIMARY SHEAVE ASSEM-
5 Primary pulley weight 8
BLY”.
6 Collar 1
7 Oil seal 2
8 Primary sliding sheave 1
9 O-ring 1
procedure.
4 - 44

SECONDARY SHEAVE

Secondary sheave disassembly Disassemble the parts in the order below.
1 Nut 1
2 Spring seat 1
3 Compression spring 1
4 Spring seat 1 Refer to “SECONDARY SHEAVE DIS-
5 Guide pin 4 ASSEMBLY/ASSEMBLY”.
6 Secondary sliding sheave 1
7 O-ring 2
8 Secondary fixed sheave 1
9 Oil seal 1
0 Oil seal 1
procedure.
4 - 45

REMOVAL
1.Loosen:
● Nut (secondary sheave) 1
● Nut (primary sheave) 2
NOTE:
● Use the sheave holder 3 to hold the pri-
mary sheave.
● First, loosen the nut (secondary sheave) 2,
then loosen the nut (primary sheave) 1.
Sheave holder:
P/N. YU-01880, 90890-01701
SECONDARY SHEAVE DISASSEMBLY

1.Remove:
● Nut 1
*********************************
Removing steps:
● Attach the sheave fixed block 2, locknut
wrench 3 and sheave spring compressor
4 to the secondary sheave assembly.
Sheave fixed block:

P/N. YM-04135, 90890-04135
Locknut wrench:
P/N. 90890-01348
Sheave spring compressor:
P/N. YM-04134, 90890-04134
● Place the sheave fixed block in a vise and

secure it.
● Tighten the sheave spring compressor nut
5 and compress the spring.
● Loosen the nut 1 with the locknut wrench
3.
● Remove the nut 1.
● Remove the sheave spring compressor
and locknut wrench.
*********************************
4 - 46

PRIMARY SHEAVE INSPECTION
1.Inspect:
● Weight outside diameter a
Out of specification → Replace the weight.
Weight outside diameter:

30 mm (1.18 in)
<Limit>: 29.5 mm (1.16 in)
2.Inspect:
● Primary puller slider
● Primary sliding sheave splines
Wear/cracks/damage → Replace.
● Spacer
● Primary puller cam
3.Inspect:
● Primary sliding sheave
● Primary fixed sheave
SECONDARY SHEAVE INSPECTION

1.Inspect:
● Secondary fixed sheave smooth operation
● Secondary sliding sheave smooth operation
Scratches/damage → Replace as a set.

2.Inspect:
● Torque cam groove 1
3.Inspect:
● Guide pin 2
4.Inspect:
● Secondary sheave spring
Damage → Replace.
5.Measure:
● Secondary sheave spring free length a
Out of specification → Replace the sec-

ondary sheave spring.
Free length:
121.4 mm (4.78 in)
<Limit>: 118.4 mm (4.66 in)
4 - 47

PRIMARY SHEAVE ASSEMBLY
1.Clean:
● Primary sliding sheave face 1
● Primary fixed sheave face 2
● Collar 3
● Weight 4
● Primary sliding sheave cam face
2.Install:
● Weight 1
NOTE:
● Apply Shell SSG-2656-2 grease (120 g) to
the whole outer surface of the weight and

install.
● Apply SSG-2656-2 grease to the inner sur-
face of the collar.

● Apply SSG-2656-2 grease to the inner sur-
face of the primary sliding sheave.

● Remove any excess grease.
3.Install:
● Spacer
● Slider 1
● Cam 2
● Primary sliding sheave cap
3 Nm (0.3 m • kg, 2.2 ft • lb)

T.
R.
SECONDARY SHEAVE ASSEMBLY

1.Apply:
● BEL-RAY assembly lube
®
(to the secondary sliding sheave 1 inner

surface and oil seals)
®
(to the bearings, oil seals and inner sur-

face of the secondary fixed sheave 2)
2.Install:
● Guide pin 1
4 - 48

3.Apply:
®
(to the guide pin sliding groove 1, and o-

ring 2 New )
4.Install:
● Spring seat
● Compression spring
● Spring seat
● Nut
*********************************
Installing steps:
● Attach the sheave fixed block, locknut
wrench and sheave spring compressor to
the secondary sheave assembly.
Sheave fixed block:

P/N. YM-04135, 90890-04135
Locknut wrench:
P/N. 90890-01348
Sheave spring compressor:
P/N. YM-04134, 90890-04134
● Place the sheave fixed block in a vise and

secure it.
● Tighten the sheave spring compressor nut
1 and compress the spring.
● Install the nut 2 and tighten it to the spec-
ified torque using the locknut wrench.
Nut:
90 Nm (9.0 m • kg, 65 ft • lb)
T.
R.
● Remove the sheave spring compressor,

locknut wrench, and sheave fixed block.
*********************************
4 - 49

INSTALLATION
1.Install:
● Secondary sheave assembly
● V-belt
● Primary sheave assembly
NOTE:
● Tightening the bolts 1 will push the sec-
ondary sliding sheave away, causing the

gap between the secondary fixed and slid-
ing sheaves to widen.
● Install the V-belt so that its arrow faces the
direction show in the illustration.
2.Tighten:
● Nut (primary sheave) 1
100 Nm (10.0 m • kg, 72 ft • lb)
T.
R.
● Nut (secondary sheave) 2
T.
R.
100 Nm (10.0 m • kg, 72 ft • lb)
NOTE:
● Use the sheave holder 3 to hold the pri-
mary sheave.
● First, tighten the nut (primary sheave) 1,
then tighten the nut (secondary sheave)

2.
Sheave holder:
P/N. YU-01880, 90890-01701
4 - 50

CLUTCH ENG
CLUTCH

Clutch removal Remove the parts in the order below.
Primary and secondary sheaves Refer to “PRIMARY AND SECONDARY
SHEAVES”.
1 Cover 1
2 Clutch housing assembly 1
3 Gasket/dowel pin 1/2 Refer to “CLUTCH REMOVAL/INSTAL-
4 One-way clutch bearing 1 LATION”.
5 Nut 1
6 Clutch carrier assembly 1
procedure.
4 - 51

CLUTCH ENG

Clutch housing disassembly Disassemble the parts in the order
below.
1 Oil seal 1
2 Circlip 1
3 Bearing housing 1
4 Circlip 1
5 Bearing 1
6 Circlip 1
7 Bearing 1
8 Clutch housing 1
procedure.
4 - 52

CLUTCH ENG
CLUTCH REMOVAL
1.Remove:
● Clutch housing assembly
● Gasket
● Dowel pins
NOTE:
Working in crisscross pattern, loosen each
bolt 1/4 of a turn. Remove them after all of
them are loosened.
2.Straighten:
● Punched portion of the nut 1.
3.Remove:
● Nut 1
NOTE:
Use a clutch holding tool 2 to hold the
clutch carrier assembly.
Clutch holding tool:

P/N. YM-91042, 90890-04086
CLUTCH INSPECTION
1.Inspect:
● Clutch housing 1
Heat damage/wear/damage → Replace.

● One-way clutch bearing 2
Chafing/wear/damage → Replace.
NOTE:
● Replace the one-way clutch assembly and
clutch housing as a set.

● The one-way clutch bearing must be
installed with the flange side facing in.
*********************************
Clutch operation:
● Install the one-way clutch bearing and
clutch carrier assembly to the clutch hous-
ing and hold the clutch carrier assembly.
● When turning the clutch housing clock-
wise Å, the clutch housing should turn
freely.
If not, the one-way clutch assembly is
faulty.
Replace it.
● When turning the clutch housing counter-
clockwise ı, the clutch housing and
crankshaft should be engaged.
If not, the one-way clutch assembly is
faulty.
Replace it.
4 - 53 *********************************

CLUTCH ENG
2.Inspect:
● Clutch shoe
Heat damage → Replace.
3.Measure:
● Clutch shoe thickness
Clutch shoe thickness:

1.5 mm (0.06 in)
Clutch shoe wear limit a:
1.0 mm (0.04 in)
CLUTCH INSTALLATION
1.Install:
● Collar
● Clutch carrier assembly
● Nut 1 New 140 Nm (14.0 m • kg, 100 ft • lb)

T.
R.
NOTE:
Use a clutch holding tool 2 to hold the
clutch carrier assembly.

P/N. YM-91042, 90890-04086
2.Lock the threads with a drift punch.
3.Install:
● One-way clutch bearing
NOTE:
The one-way clutch bearing should be
installed in the clutch carrier assembly with
the arrow mark a facing toward the clutch
housing.
4 - 54

CLUTCH ENG
4.Install:
● Dowel pins
● Gasket New
● Clutch housing assembly
10 Nm (1.0 m • kg, 7.2 ft • lb)
T.
R.
NOTE:
● Tighten the bolts in stages, using a criss-
cross pattern.
● After tightening the bolts, check that the
clutch housing assembly to counterclock-

wise rotates smoothly.
4 - 55

CRANKCASE ENG
CRANKCASE
STARTER MOTOR, TIMING CHAIN AND OIL FILTER

Starter motor, timing chain and oil Remove the parts in the order below.
filter removal
Engine assembly Refer to “ENGINE REMOVAL”.
Cylinder head Refer to “CYLINDER HEAD”.
Cylinder and piston Refer to “CYLINDER AND PISTON”.
Recoil starter and CDI rotor Refer to “RECOIL STARTER AND CDI
MAGNETO”.
Primary and secondary sheaves Refer to “PRIMARY AND SECONDARY
SHEAVES”.
Clutch carrier assembly Refer to “CLUTCH”.
1 Oil pump drive gear/straight key 1/1 Refer to “OIL PUMP DRIVE GEAR
2 Oil pump driven gear 1
3 Timing chain guide 1
4 Timing chain 1
5 Starter motor/O-ring 1/1
4 - 56

CRANKCASE ENG

6 Oil filter 1
7 Speed sensor 1
8 Shift cam stopper 1
9 Neutral switch 1
10 Park switch 1
11 Reverse switch 1
12 Oil filler cap 1
13 Bearing cover/gasket 1/1
14 Oil delivery pipe 1
15 Drain plug/O-ring 1/1
17 Oil strainer 1
procedure.
4 - 57

CRANKCASE ENG
CRANKCASE

Crankcase separation Remove the parts in the order below.
1 Shift lever cover/gasket 1/1
Refer to “SHIFT LEVER INSTALLA-
2 Shift lever 1/O-ring 1/1
TION”.
3 Shift lever 2 assembly 1
4 Crankcase (left) 1
Refer to “CRANKCASE SEPARATION/
5 Dowel pin 2
ASSEMBLY”.
6 Crankcase (right) 1
procedure.
4 - 58

CRANKCASE ENG
CRANKCASE BEARING

Crankcase bearing removal Remove the parts in the order below.
Crankshaft and oil pump Refer to “CRANKSHAFT AND OIL
PUMP”.
Transmission Refer to “TRANSMISSION”.
Middle drive/driven shaft Refer to “MIDDLE GEAR”.
1 Oil seal 2
2 Bearing retainer 2
3 Bearing 10
procedure.
4 - 59

CRANKCASE ENG
OIL PUMP DRIVE GEAR REMOVAL
1.Straighten:
● Lock washer tab
2.Remove:
● Oil pump drive gear nut
*********************************
Removal steps:
● Temporaly install the clutch carrier
assembly 1.
● Hold the clutch carrier assembly with a
clutch holding tool 2 and loosen the oil
pump drive gear nut.

P/N. YM-91042, 90890-04086
● Remove the clutch carrier assembly.

*********************************
Å CRANKCASE SEPARATION
1.Separate:
● Left crankcase
● Right crankcase
*********************************
Separation steps:
● Remove the crankcase bolts.
NOTE:
● Loosen each bolt 1/4 of a turn at a time
and after all the bolts are loosened,

ı
remove them.
● Loosen the bolts in stages, using a criss-
cross pattern.
Å Left crankcase
ı Right crankcase
4 - 60

CRANKCASE ENG
● Remove the left crankcase.
CAUTION:
Use a soft hammer to tap on one side of
the crankcase. Tap only on reinforced por-
tions of the crankcase. Do not tap on the
crankcase mating surfaces. Work slowly
and carefully. Make sure that the crankcase
halves separate evenly.
● Remove the dowel pins.
*********************************
TIMING CHAIN AND GUIDE INSPECTION

1.Inspect:
● Timing chain
Cracks/stiff → Replace the timing chain

and camshaft sprocket as a set.
2.Inspect:
● Intake side timing chain guide
OIL STRAINER AND OIL DELIVERY PIPE

INSPECTION
1.Inspect:
● Oil strainer 1
● O-rings 2
Damage → Replace.
2.Inspect:
● Oil delivery pipe
Clogged → Blow out with compressed air.
4 - 61

CRANKCASE ENG
CRANKCASE INSPECTION
1.Thoroughly wash the case halves in a
mild solvent.
2.Clean all the gasket mating surfaces and
crankcase mating surfaces thoroughly.
3.Inspect:
● Crankcase
● Oil delivery passages
Clogged → Blow out with compressed air.

BEARINGS AND OIL SEALS INSPECTION
1.Inspect:
● Bearing
Clean and lubricate, then rotate the inner

race with a finger.
Roughness → Replace.
2.Inspect:
● Oil seals
CRANKCASE ASSEMBLY
1.Apply:
®
● Sealant (Quick Gasket ) 1
(to the mating surfaces of both case

halves)
Sealant (Quick Gasket®):

P/N. ACC-11001-05-01
Yamaha bond No. 1215:
P/N. 90890-85505
2.Install:
● Dowel pin 2
3.Fit the left crankcase onto the right case.

Tap lightly on the case with a soft hammer.
CAUTION:
Before installing and torquing the crank-
case holding bolts, be sure to check
whether the transmission is functioning
properly by manually rotating the shift cam
in both directions.
4 - 62

CRANKCASE ENG
Å 4.Tighten:
● Crankcase bolts
(follow the proper tightening sequence)

10 Nm (1.0 m • kg, 7.2 ft • lb)
T.
R.
Å Right crankcase
ı Left crankcase
NOTE:
Tighten the bolts in stages, using a criss-
cross pattern.
5.Apply:
● 4-stroke engine oil
(to the crank pin, bearing and oil delivery

hole)
6.Check:
● Crankshaft and transmission operation
Unsmooth operation → Repair.
SHIFT LEVER INSTALLATION

1.Install:
● Shift lever 2 assembly 1
14 Nm (1.4 m • kg, 10 ft • lb)

T.
R.
● Shift lever 1 2
NOTE:
When installing the shift lever 1, align the
punch mark a on the shift lever 1 with the
punch marks b on the shift lever 2.
4 - 63

CRANKCASE ENG
OIL PUMP DRIVE GEAR INSTALLATION
1.Install:
● Straight key
● Oil pump drive gear
● Lock washer New
2.Tighten:
50 Nm (5.0 m • kg, 36 ft • lb)
T.
R.
*********************************
Tightening steps:
● Temporary install the clutch carrier
assembly 1.
● Hold the clutch carrier assembly with a
clutch holding tool 2 and tighten the oil
pump drive gear nut.

P/N. YM-91042, 90890-04086
● Remove the clutch carrier assembly.

*********************************
3.Bend the lock washer tab.
4 - 64

CRANKSHAFT AND OIL PUMP ENG
CRANKSHAFT AND OIL PUMP

Crankshaft and oil pump removal Remove the parts in the order below.
Crankcase separation Refer to “CRANKCASE”.
1 Washer/circlip 1/1
2 Oil pump assembly/gasket 1/1
3 Balancer 1 Refer to “CRANKSHAFT REMOVAL/
4 Crankshaft seal 2 CRANKSHAFT AND BALANCER
5 Crankshaft 1 INSTALLATION”.
procedure.
4 - 65

OIL PUMP

Oil pump disassembly Disassemble the parts in the order
below.
1 Rotor cover 1
2 Pin 2
3 Shaft 1
4 Pin 1
5 Inner rotor 1
6 Outer rotor 1
7 Oil pump housing 1
procedure.
4 - 66

CRANKSHAFT REMOVAL
1.Remove:
● Crakshaft seal 1
NOTE:
Mark a note of the pasition of each crank-
shaft seal so that they can be installed in
the correct place and in the correct direc-
tion.
2.Remove:
● Crankshaft
Use a crankcase separating tool 1.
Crankcase separating tool:

P/N. YU-01135-A, 90890-01135
OIL PUMP INSPECTION

1.Inspect:
● Oil pump driven gear
● Rotor housings
● Rotor cover
Cracks/wear/damage → Replace.
2.Measure:
● Tip clearance a
(between the inner rotor 1 and the outer

rotor 2)
● Side clearance b
(between the outer rotor 2 and the pump

housing 3)
Out of specification → Replace the oil
pump.
Tip clearance a:
0.15 mm (0.006 in)
<Limit>: 0.2 mm (0.008 in)
Side clearance b:
0.04 ~ 0.09 mm (0.002 ~ 0.004 in)
4 - 67

3.Check:
● Oil pump operation
Unsmooth → Repeat steps #1 and #2 or

replace the defective parts.
CRANKSHAFT INSPECTION
1.Measure:
● Crank width A
Out of specification → Replace the crank-

shaft.
Crank width:
62.95 ~ 63.00 mm
(2.478 ~ 2.480 in)
● Side clearance D
shaft.
Big end side clearance:

0.25 ~ 0.75 mm (0.010 ~ 0.030 in)
<Limit>: 1.0 mm (0.040 in)
● Runout C
shaft.
Runout limit:
C1: 0.03 mm (0.0012 in)
C2: 0.03 mm (0.0012 in)
*********************************
Crankshaft reassembling point:
The crankshaft 1 and the crank pin 2 oil
passages must be properly interconnected
with a tolerance of less than 1 mm (0.04 in).
*********************************
CAUTION:
The buffer boss and woodruff key should
be replaced when removed from the crank-
shaft.
4 - 68

CRANKSHAFT AND BALANCER
INSTALLATION
1.Install:
● Crankshaft
Crankshaft installer set 1:

P/N. YU-90050
Buffer boss installer set 2:
P/N. 90890-04088
Adapter #11 3:
P/N. YM-33279
Crank pot spacer 4:
P/N. YM-90070-A, 90890-04060
NOTE:
Hold the connecting rod at the Top Dead
Center (T.D.C.) with one hand while turning
the nut of the installing tool with the other.
Operate the installing tool until the crank-
shaft bottoms against the bearing.
CAUTION:
Apply engine oil to each bearing to protect
the crankshaft against scratches and to
make installation easier.
2.Install:
● Crankshaft seal
NOTE:
Install the crankshaft seals in the correct
place and in the correct direction.
3.Install:
● Balancer 1
NOTE:
Align the punch marks a on the drive and
driven gear.
4 - 69

TRANSMISSION ENG
TRANSMISSION

Transmission removal Remove the parts in the order below.
1 Driven sprocket 1
2 Drive sprocket 1
3 Chain 1
4 Clutch dog 2 1
5 Shift fork “L” 1
6 Spring 1
7 Low wheel gear 1
8 Secondary shaft 1
9 Middle driven gear 1
10 Drive axle assembly 1
11 Guide bar 1
4 - 70

TRANSMISSION ENG

12 Shift fork “R” 1
13 Spring 1
14 Shift cam 1
15 Stopper wheel 1
16 Clutch dog 1 1
17 High wheel gear 1
18 Stopper lever 1
19 Spacer/O-ring 1/1
procedure.
4 - 71

TRANSMISSION ENG
SHIFT FORK INSPECTION
1.Inspect:
● Shift fork cam follower 1
● Shift fork pawl 2
Scoring/bends/wear/damage → Replace.
2.Inspect:
● Guide bar
Roll the guide bar on a flat surface.

Bends → Replace.
WARNING
Do not attempt to straighten a bent guide
bar.
3.Check:
● Shift fork movement
(on the guide bar)

Unsmooth operation → Replace the shift
fork and the guide bar.
4.Inspect:
● Spring
SHIFT CAM INSPECTION

1.Inspect:
● Shift cam grooves
Scratches/wear/damage → Replace.
4 - 72

TRANSMISSION ENG
TRANSMISSION INSPECTION
1.Measure:
● Axle runout
Use a centering device and a dial gauge.

Out of specification → Replace the bent
axle.
Runout limit (drive axle):

0.03 mm (0.001 in)
2.Inspect:
● Gear teeth
Blue discoloration/pitting/wear →
Replace.
● Mated dogs
Rounded edges/cracks/missing portions

→ Replace.
3.Check:
● Gear movement
Unsmooth → Repeat steps #1 and #2 or

replace the defective parts.
4.Inspect:
● Circlip
Bends/looseness/damage → Replace.
TRANSMISSION INSTALLATION
1.Install:
● Shift cam
● Washer
● Spring (short)
● Shift fork “R” 1
● Drive axle assembly 2
● Guide bar 3
● Clutch dog 2 4
● Spring (long) 5
● Shift fork “L” 6
NOTE:
Install the shift fork with the “R” mark fac-
ing towards the right side of the crankcase
and the shift fork with the “L” mark facing
towards the left side of the crankcase. Be
sure that the shift fork guide pin is properly
seated in the shift drum groove.
4 - 73

TRANSMISSION ENG
2.Check:
● Shift operation
Unsmooth operation → Repair.

NOTE:
● Oil each gear and bearing thoroughly.
● Before assembling the crankcase, be sure
that the transmission is in neutral and that

the gears turn freely.
4 - 74

MIDDLE GEAR ENG
MIDDLE GEAR
MIDDLE DRIVE SHAFT

Middle drive shaft removal Remove the parts in the order below.
Transmission Refer to “TRANSMISSION”.
1 Bearing housing assembly 1
2 Nut 1 Refer to “MIDDLE DRIVE SHAFT
3 Middle drive pinion gear 1 REMOVAL/INSTALLATION”.
4 Shim Refer to “MIDDLE DRIVE AND DRIVEN
GEAR SHIM SELECTION”.
5 Middle drive shaft 1
procedure.
4 - 75

MIDDLE GEAR ENG
MIDDLE DRIVEN SHAFT

Middle driven shaft assembly Remove the parts in the order below.
1 Circlip 2
2 Bearing 2
Refer to “MIDDLE DRIVEN SHAFT
3 Universal joint 1
4 Universal joint yoke 1
5 Bearing housing/O-ring 1/1
6 Shim Refer to “MIDDLE DRIVE AND DRIVEN
GEAR SHIM SELECTION”.
7 Middle drive pinion gear 1 Refer to “MIDDLE DRIVEN SHAFT
8 Bearing retainer 1 REMOVAL/INSTALLATION”.
9 Damper cam 1
10 Spring 1
11 Gear coupling 1
4 - 76

MIDDLE GEAR ENG

12 Front drive shaft coupling 1
14 Middle driven shaft 1
procedure.
4 - 77

MIDDLE GEAR ENG
MIDDLE DRIVE SHAFT REMOVAL
1.Straighten:
● Punched portion of the nut (middle drive
pinion gear)
2.Loosen:
● Nut (middle drive pinion gear) 1
NOTE:
Secure the middle drive shaft in the vise
with a clean rag.
3.Remove:
● Nut (middle drive pinion gear)
● Middle drive pinion gear
● Shim(s)
MIDDLE DRIVEN SHAFT REMOVAL

1.Remove:
● Universal joint
*********************************
Universal joint removal steps:
● Remove the circlips 1.
● Place the U-joint in a press.
● With a suitable diameter pipe 2 beneath
the yoke 3, press the bearing 4 into the
pipe as shown.
NOTE:
It may be necessary to lightly tap the yoke
with a punch.
● Repeat
the steps for the opposite bearing.
● Remove the yoke.
NOTE:
It may be necessary to lightly tap the yoke
with a punch.
*********************************
4 - 78

MIDDLE GEAR ENG
2.Remove:
● Nut 1
● Washer
● Universal joint yoke
NOTE:
Use the universal joint holder 2 to hold the
universal joint yoke.
Universal joint holder:

P/N. YM-04062, 90890-04062
3.Remove:
● Bearing housing assembly 1
*********************************
Bearing housing removal steps:
● Clean the outside of the middle driven
shaft.
● Place the middle driven shaft onto a
hydraulic press.
CAUTION:
● Never directly press the shaft end with a
hydraulic press, this will result in damage
to the shaft thread.
● Install the suitable socket 2 on the shaft
end to protect the thread from damage.
● Press the shaft end and remove the bear-
ing housing.
*********************************
4.Remove:
● Bearing retainer
● Bearing
*********************************
Removal steps:
● Attach the folded rag 1.
● Secure the bearing housing edge in the vise.
● Attach the bearing retainer wrench 2.
Bearing retainer wrench:

P/N. YM-04128, 90890-04128
CAUTION:
The middle driven shaft bearing retainer
has left-handed threads. To loosen the
retainer turn it clockwise.
● Remove the bearing retainer and bearing.
*********************************
4 - 79

MIDDLE GEAR ENG
5.Remove:
● Front drive shaft coupling
● Bearing retainer 1
● Bearing 2
NOTE:
Attach the ring nut wrench 3.
Ring nut wrench:

P/N. YM-38404, 90890-01430
CAUTION:
has left-handed threads. To loosen the
retainer turn it clockwise.
6.Remove:
● Middle drive shaft 1
(with bearing)
INSPECTION
1.Inspect:
● Damper cam surfaces
Wear/scratches → Replace damper and

driven pinion gear as a set.
2.Inspect:
● Damper spring
Damage/cracks → Replace.
3.Inspect:
● Gear teeth (drive pinion gear) 1
● Gear teeth (driven pinion gear) 2
Pitting/galling/wear → Replace.
4 - 80

MIDDLE GEAR ENG
4.Inspect:
● O-ring
Damage → Replace.
● Bearings
Pitting/damage → Replace.
5.Check:
● U-joint movement
Roughness → Replace U-joint.
MIDDLE DRIVE AND DRIVEN GEAR SHIM

SELECTION
When the drive and driven gear, bearing
housing assembly and/or crankcase
replaced, be sure to adjust the gear shim 1.
1.Select:
● Middle drive gear shim 1
● Middle driven gear shim 2
*********************************
Middle drive and driven gear shim selection
steps:
● Position middle drive and driven gear by
using shims 1 and 2 with their respec-
tive thickness calculated from information
marked on crankcase, bearing housing
and drive gear end.
1 Shim thickness “A”
2 Shim thickness “B”
● Tofind shim thickness “A” use following
formula:
Middle drive pinion gear shim thickness:

“A” = c – a – b
Where:
a = a numeral (usually a decimal num-
ber) on the bearing housing is either
added to or subtracted from “10.5”.
b = drive pinion gear to driven pinion
gear center distance (considered
constant).
c = a numeral (usually a decimal num-
ber) on the right crankcase specifies
a thickness of “66”.
4 - 81

MIDDLE GEAR ENG
Example:
1) If the bearing housing is marked “+04”,
..... a is 10.54,
2) b is 55
3) If the crankcase (right) is marked
“66.03”,
..... c is 66.03.
4) Therefore, the shim thickness is 0.47 mm.
A = 66.03 – 10.54 – 55
= 0.49
5) Round off hundredths digit and select

appropriate shim(s).
In the example above, the calculated
shim thickness is 0.49 mm. The chart
instructs you, however, to round off 9 to
10.
Hundredths Round value

0, 1, 2 0
3, 4, 5, 6, 7 5
8, 9 10
Shims are supplied in the following thick-

ness.
Middle drive pinion gear shim
0.10 0.30
Thickness (mm) 0.15 0.40
0.20 0.50
● Tofind shim thickness “B” use the follow-

ing formula:
Middle driven pinion gear shim thick-

ness:
“B” = d – e + f – g – 0.05
4 - 82

MIDDLE GEAR ENG
Where:
d = a numeral (usually a decimal num-
ber) on the bearing housing is either
added to or subtracted from “76”.
e = a numeral (usually a decimal num-
ber) on the middle driven pinion
gear is either added to or subtracted
from “59”.
f = a numeral (usually a decimal num-
ber) on the middle driven pinion
gear is either added to or subtracted
from “79.5”.
g = a numeral (usually a decimal num-
ber) on the left crankcase specifies a
thickness of “95.8”.
Example:
1) If the bearing housing is marked “+03”,
..... d is 76.03.
2) If the driven pinion gear is marked “+02”,
..... e is 59.02.
3) If the driven pinion gear is marked “–10”,
..... f is 79.40.
4) If the crankcase (left) is marked “95.79”,
..... g is 95.79.
5) Therefore, the shim thickness is 0.63 mm.
B = 76.03 – 59.02 + 79.40 – 95.79 – 0.05

= 0.57
6) Round off hundredths digit and select

appropriate shim(s).
shim thickness is 0.57 mm. The chart
instructs you, however, to round off 7
to 5.
Hundredths Round value
0, 1, 2 0
3, 4, 5, 6, 7 5
8, 9 10
4 - 83

MIDDLE GEAR ENG
ness.
Middle drive pinion gear shim
0.10 0.40
0.20 0.60
0.30
*********************************
MIDDLE DRIVEN SHAFT INSTALLATION

1.Install:
● Bearing retainer 1 LT
80 Nm (8.0 m • kg, 58 ft • lb)

T.
R.
NOTE:
Attach the ring nut wrench 2.
Ring nut wrench:

P/N. YM-38404, 90890-01430
CAUTION:
has left-handed threads. To tighten the
retainer turn it counterclockwise.
2.Install:
● Bearing retainer 1 LT
*********************************
Installation steps:
● Secure the bearing housing edge in the
vise with a clean 2.
● Attach the bearing retainer wrench 3.

P/N. YM-04128, 90890-04128
4 - 84

MIDDLE GEAR ENG
● Tighten the bearing retainer.
CAUTION:
has left-handed threads. To tighten the
retainer turn it counterclockwise.
Bearing retainer:
110 Nm (11.0 m • kg, 80 ft • lb)
T.
R.
*********************************
3.Install:
● Shims 1
● Bearing housing
NOTE:
Install the shims so that the tabs are posi-
tioned as shown in the illustration.
4.Install:
● Universal joint yoke (rear side)
● Washer
● Nut 1 LT
97 Nm (9.7 m • kg, 70 ft • lb)
T.
R.
NOTE:
Use the universal joint holder 2 to hold the
yoke.
Universal joint holder:

P/N. YM-04062, 90890-04062
5.Install:
● Universal joint
*********************************
Universal joint installation steps:
● Install the opposite yoke into the U-joint.
● Apply wheel bearing grease to the bear-
ings.
4 - 85

MIDDLE GEAR ENG
● Install the bearing 1 onto the yoke.
CAUTION:
Check each bearing. The needles can easily
fall out of their races. Slide the yoke back
and forth on the bearings; the yoke will not
go all the way onto a bearing if a needle is
out of place.
● Presseach bearing into the U-joint using a
suitable socket.
NOTE:
The bearing must be inserted far enough
into the U-joint so that the circlip can be
installed.
● Install
the circlips 2 into the groove of
each bearing.
*********************************
MIDDLE DRIVE SHAFT INSTALLATION

1.Tighten:
● Nut (middle drive pinion gear) 1 New
145 Nm (14.5 m • kg, 105 ft • lb)

T.
R.
NOTE:
Secure the middle drive shaft in the vise
with a clean rag.
2.Lock the threads with a drift punch.
GEAR LASH MEASUREMENT

1.Measure:
● Gear lash
Middle gear lash:

0.1 ~ 0.3 mm (0.004 ~ 0.012 in)
*********************************
Measurement steps:
● Temporaly install the left crankcase.
● Attach the pinion gear fix clamp 1 to the
middle drive shaft.
Pinion gear fix clamp:

P/N. YM-04129, 90890-04129
4 - 86

MIDDLE GEAR ENG
● Attach the gear lash measurement tool 2
and dial gauge 3.
Gear lash measurement tool:

P/N. YM-01467, 90890-01467
a 46 mm (1.8 in)
● Measure the gear lash while rotating the
middle driven shaft back and forth.
NOTE:
Measure the gear lash at 4 positions. Rotate
the middle driven gear 90˚ each time.
● Ifthe gear lash is incorrect, adjust the gear
lash by middle driven pinion gear shims
and/or middle drive pinion gear shim(s).
*********************************
4 - 87

ENG
4 - 88

COOL
5
COOL
CHAPTER 5.
COOLING SYSTEM
RADIATOR .....................................................................................................5-1
RADIATOR INSPECTION ......................................................................5-3
RADIATOR INSTALLATION .................................................................5-4
THERMOSTAT ..............................................................................................5-5
THERMOSTAT INSPECTION ...............................................................5-6
THERMOSTAT INSTALLATION ...........................................................5-6
WATER PUMP ...............................................................................................5-7

WATER PUMP DISASSEMBLY ............................................................5-9
WATER PUMP INSPECTION ................................................................5-9
WATER PUMP ASSEMBLY ................................................................5-10

COOL

RADIATOR COOL
COOLING SYSTEM
RADIATOR

Radiator removal Remove the parts in the order below.
Seat and side panels Refer to “SEAT AND SIDE PANELS” in
CHAPTER 3.
Front carrier, front bumper and front Refer to “FRONT CARRIER, FRONT
fender BUMPER AND FRONT FENDER” in
CHAPTER 3.
CHAPTER 3.
Coolant Drain.
Refer to “COOLANT REPLACEMENT”
in CHAPTER 3.
1 Radiator fan coupler 1 Disconnect.
2 Thermo switch coupler 1 Disconnect.
3 Coolant reservoir hose 1 Disconnect.
4 Radiator fan breather hose 1
5-1

RADIATOR COOL

5 Radiator inlet hose 1 Disconnect.
6 Radiator outlet hose 1 Disconnect.
7 Radiator 1
8 Radiator fan 1
9 Thermo switch 1
procedure.
5-2

RADIATOR COOL
RADIATOR INSPECTION
1.Inspect:
● Radiator fins
Obstruction → Clean.
Apply compressed air to the rear of the
radiator.
Damage → Repair or replace.
NOTE:
Straighten any flattened fins with a thin,
flat-head screwdriver.
2.Inspect:
● Radiator hoses
3.Measure:
● Radiator cap opening pressure
Below the specified pressure → Replace
the radiator cap.
Radiator cap opening pressure:

93.3 ~ 122.7 kPa
(0.933 ~ 1.227 kg/cm2,
13.53 ~ 17.79 psi)
*********************************
Measurement steps:
● Install the radiator cap tester 1 and
adapter 2 onto the radiator cap 3.
Radiator cap tester:

P/N. YU-24460-01, 90890-01325
Adapter:
P/N. YU-33984, 90890-01352
● Apply the specified pressure for ten sec-

onds and make sure that there is no drop
in pressure.
*********************************
4.Check:
● Radiator fan
Damage → Replace.
Malfunction → Check and repair.
Refer to “COOLING SYSTEM” in CHAP-
TER 9.
5-3

RADIATOR COOL
RADIATOR INSTALLATION
1.Fill:
● Cooling system

mended coolant)
Refer to “COOLANT REPLACEMENT” in
CHAPTER 3.
2.Check:
● Cooling system
Leaks → Repair or replace any faulty part.
5-4

THERMOSTAT COOL
THERMOSTAT

Thermostat removal Remove the parts in the order below.
Seat and fuel tank side panel (right) Refer to “SEAT AND SIDE PANELS” in
CHAPTER 3.
Coolant Drain.
Refer to “COOLANT REPLACEMENT”
in CHAPTER 3.
1 Radiator inlet hose 1
2 Thermostat cover 1
3 Thermostat 1
procedure.
5-5

THERMOSTAT COOL
THERMOSTAT INSPECTION
1.Check:
● Thermostat 1
Does not open at 63.5 ~ 65.5 ˚C (146.3 ~

149.9 ˚F) → Replace.
*********************************
Checking steps:
● Suspend the thermostat in a container
filled with water.
● Slowly heat the water.
● Place a thermometer in the water.
● While stirring the water, observe the ther-
mostat and thermometer’s indicated tem-
perature.
*********************************
1 Thermostat
2 Thermometer
3 Water
4 Container
Å Fully closed
ı Fully open
NOTE:
If the accuracy of the thermostat is in doubt,
replace it. A faulty thermostat could cause
serious overheating or overcooling.
2.Inspect:
● Thermostat housing cover
● Thermostat housing
THERMOSTAT INSTALLATION
1.Install:
● Thermostat 1
● Thermostat housing cover
NOTE:
Install the thermostat with its breather hole
a toward the projection b.
2.Fill:
● Cooling system
mended coolant)
Refer to “COOLANT REPLACEMENT” in
CHAPTER 3.
3.Check:
● Cooling system
Leak → Repair or replace any faulty part.
5-6

WATER PUMP COOL
WATER PUMP

Water pump removal Remove the parts in the order below.
Seat, fuel tank side panel (left) and Refer to “SEAT AND SIDE PANELS” in
engine side cover CHAPTER 3.
CHAPTER 3.
1 Water pump outlet hose 1
2 Water pump outlet pipe 1
3 O-ring 1
4 Water pump inlet hose 1
5 Water pump assembly 1
6 O-ring 1
procedure.
5-7

WATER PUMP COOL

Water pump disassembly Remove the parts in the order below.
1 Water pump housing cover 1
2 Gasket 1
3 Circlip 1
4 Impeller 1
5 Rubber damper holder 1
6 Rubber damper 1
7 Water pump seal 1
8 Oil seal 1
9 Bearing 1
0 Water pump housing 1
procedure.
5-8

WATER PUMP COOL
WATER PUMP DISASSEMBLY
1.Remove:
● Rubber damper holder 1
● Rubber damper 2
(from the impeller, with a thin, flathead

screwdriver)
NOTE:
Do not scratch the impeller shaft.
2.Remove:
● Water pump seal 1
NOTE:
Tap out the water pump seal from the
inside of the water pump housing.
2 Water pump housing
3.Remove:
● Oil seal 1
● Bearing 2
NOTE:
Tap out the bearing and oil seal from the
outside of the water pump housing.
3 Water pump housing
WATER PUMP INSPECTION

1.Inspect:
● Water pump housing cover 1
● Water pump housing 2
● Impeller 3
● Rubber damper 4
● Rubber damper holder 5
Cracks/damage/wear → Replace.
2.Inspect:
● Water pump seal
● Oil seal
● Water pump outlet pipe
Cracks/damage/wear → Replace.
● Bearing
Rough movement → Replace.
5-9

WATER PUMP COOL
WATER PUMP ASSEMBLY
1.Install:
● Oil seal 1 New
(into the water pump housing 2)
NOTE:
● Before installing the oil seal, apply tap
water or coolant onto its outer surface.

● Install the oil seal with a socket 3 that
matches its outside diameter.
2.Install:
● Water pump seal 1 New
(into the water pump housing 2)
CAUTION:
Never lubricate the water pump seal sur-
face with oil or grease.
NOTE:
Install the water pump seal with the special
tools.
Mechanical seal installer 3:

P/N. YM-33221, 90890-04078
Middle driven shaft bearing driver
4:
P/N. YM-04058-1, 90890-04058
Å Push down.
3.Install:
● Rubber damper 1 New
● Rubber damper holder 2 New
NOTE:
Before installing the rubber damper, apply
tap water or coolant onto its outer surface.
5 - 10

WATER PUMP COOL
4.Measure:
● Impeller shaft tilt
Out of specification → Repeat steps (3)

and (4).
CAUTION:
Make sure that the rubber damper and rub-
ber damper holder are flush with the impel-
ler.
Max. impeller shaft tilt:

0.15 mm (0.006 in)
1 Straightedge
2 Impeller
5 - 11

COOL
5 - 12

CARB
6
CARB
CHAPTER 6.
CARBURETION
CARBURETOR ...............................................................................................6-1
CARBURETOR INSPECTION ................................................................6-4
CARBURETOR ASSEMBLY ..................................................................6-6
FUEL LEVEL ADJUSTMENT ................................................................6-7

CARB

CARBURETOR CARB
CARBURETION
CARBURETOR

Carburetor removal Remove the parts in the order below.
Seat/fuel tank side panels/fuel tank/ Refer to “SEAT, CARRIERS, FENDERS
rubber cover AND FUEL TANK” in CHAPTER 3.
1 Drain hose 1
2 Starter cable/starter plunger 1/1
3 Air vent hose 1
4 Carburetor assembly 1
5 Throttle valve cover 1
6 Throttle cable end 1
7 Throttle cable 2 NOTE:
After removing the carburetor assem-
bly, remove the throttle cable.
procedure.
6-1

CARBURETOR CARB

Carburetor disassembly Disassemble the parts in the order
below.
1 Air vent hose 1
2 Throttle stop screw 1
3 Vacuum chamber cover 1
4 Spring 1
5 Jet needle holder 1
6 Spring 1
7 Jet needle set 1
8 Piston valve 1
9 Coasting enricher 1
0 Float chamber 1
A Drain screw 1
B Float 1 Refer to “CARBURETOR ASSEMBLY”.
C Needle valve set 1
6-2

CARBURETOR CARB

D Pilot jet 1
E Pilot screw set 1 Refer to “CARBURETOR ASSEMBLY”.
F Main jet 1
G Needle jet 1 Refer to “CARBURETOR DISASSEM-
BLY/ASSEMBLY”.
H Starter jet 1
I Pilot air jet 1
procedure.
6-3

CARBURETOR CARB
CARBURETOR INSPECTION
1.Inspect:
● Carburetor body
● Float chamber
● Fuel passage
Contamination → Clean as indicated.

● Fuel chamber body
Contamination → Clean.
*********************************
Cleaning steps:
● Wash the carburetor in a petroleum based
solvent.
(Do not use any caustic carburetor clean-
ing solution.)
● Blow out all of the passages and jets with
compressed air.
*********************************
2.Inspect:
● Float 1
● Float tang 2
Damage → Replace.
3.Inspect:
● Valve seat 1
● Needle valve 2
● O-ring 3
Contamination/wear/damage → Replace
as a set.
NOTE:
Always replace the needle valve and valve
seat as a set.
4.Inspect:
● Piston valve 1
Scratches/wear/damage → Replace.
● Rubber diaphragm 2
Tears → Replace.
6-4

CARBURETOR CARB
5.Inspect:
● Vacuum chamber cover 1
● Spring 2
6.Inspect:
● Diaphragm (coasting enricher) 1
● Spring 2
● Cover 3
Tears (diaphragm)/damage → Replace.
7.Inspect:
● Jet needle 1
● Main jet 2
● Needle jet 3
● Pilot air jet 4
● Pilot jet 5
● Pilot screw 6
● Starter jet 7
● Starter plunger 8
Bends/wear/damage → Replace.
● Blockage → Blow out the jets with com-
pressed air.
8.Check:
● Free movement (piston valve)
Sticks → Replace the piston valve guide

and the piston valve.
Insert the piston valve into the carburetor
body, and check for free movement.
9.Check:
● Free movement (throttle valve)
Sticks → Replace.
6-5

CARBURETOR CARB
CARBURETOR ASSEMBLY
CAUTION:
Before reassembling, wash all of the parts
in a clean petroleum based solvent.
1.Install:
● Pilot screw 1
Pilot screw:
2-1/2 turns out
2.Measure:
● Float height a
Float height (F.H.):

13 mm (0.51 in)
*********************************
Measurement and adjustment steps:
● Hold the carburetor in an upside down
position.
● Measure the distance from the front mat-
ing surface of the float chamber (gasket
removed) to the top of the float.
NOTE:
The float arm should be resting on the nee-
dle valve, but not compressing it.
● If the float height is not within the specifi-
cation, inspect the valve seat and needle
valve.
● If either is worn, replace them both.
● If both are fine, adjust the float height by
bending the float tang 1 on the float.
● Recheck the float height.
*********************************
6-6

CARBURETOR CARB
FUEL LEVEL ADJUSTMENT
1.Measure:
● Fuel level a
Fuel level:
2.0 ~ 3.0 mm (0.08 ~ 0.12 in)
Above the float chamber mat-
ing surface
*********************************
Fuel level measurement and adjustment
steps:
● Place the machine on a level surface.
● Connect the fuel level gauge 1 to the
drain pipe 2.
Fuel level gauge:

P/N. YM-01312-A, 90890-01312
● Loosen the drain screw 3.

● Hold the gauge vertically next to the float
chamber line.
● Measure the fuel level a with the gauge.
● If the fuel level is incorrect, adjust the fuel
level.
● Remove the carburetor.
● Inspect the valve seat and needle valve.
● If either is worn, replace them both.
● If both are fine, adjust the float level by
bending the float tang 4 slightly.
● Install the carburetor.
● Recheck the fuel level.
*********************************
6-7

CARB
6-8

DRIVE
7
DRIV
CHAPTER 7.
DRIVE TRAIN
TROUBLESHOOTING ...................................................................................7-1
CONSTANT VELOCITY JOINTS AND DIFFERENTIAL GEAR ....................7-4

RING GEAR REMOVAL ........................................................................7-9
CONSTANT VELOCITY JOINT INSPECTION ......................................7-9
DIFFERENTIAL GEAR INSPECTION ....................................................7-9
CONSTANT VELOCITY JOINT ASSEMBLY ......................................7-10
DIFFERENTIAL GEAR ASSEMBLY ....................................................7-11
DIFFERENTIAL GEAR LASH MEASUREMENT AND
ADJUSTMENT ................................................................................7-11
DIFFERENTIAL GEAR OPERATION CHECK ......................................7-13
REAR AXLE/FINAL DRIVE GEAR AND DRIVE SHAFT .............................7-14

REAR AXLE REMOVAL ......................................................................7-17
FINAL DRIVE GEAR DISASSEMBLY .................................................7-17
FINAL DRIVE ROLLER BEARING REMOVAL AND REASSEMBLY ..7-18
FINAL DRIVE PINION GEAR AND RING GEAR POSITIONING ........7-19
REAR AXLE INSPECTION ..................................................................7-23
DRIVE SHAFT INSPECTION ...............................................................7-24
FINAL DRIVE GEAR INSPECTION .....................................................7-24
FINAL GEAR LASH MEASUREMENT AND ADJUSTMENT ............7-25
FINAL DRIVE GEAR ASSEMBLY .......................................................7-27
FINAL DRIVE GEAR INSTALLATION .................................................7-27

DRIV

TROUBLESHOOTING DRIV
DRIVE TRAIN
TROUBLESHOOTING
The following conditions may indicate damaged shaft drive components:
Symptoms Possible Causes
1.A pronounced hesitation or “jerky” move- A.Bearing damage.
ment during acceleration, deceleration, or
B.Improper gear lash.
sustained speed. (This must not be con-
fused with engine surging or transmission C.Gear tooth damage.
characteristics.)
D.Broken drive shaft.
2.A “rolling rumble” noticeable at low speed;
a high-pitched whine; a “clunk” from a E. Broken gear teeth.
shaft drive component or area.
F. Seizure due to lack of lubrication.
3.A locked-up condition of the shaft drive
train mechanism, no power transmitted G.Small foreign objects lodged between the
from the engine to the front and/or rear moving parts.
wheel.
NOTE:
Areas A, B, and C above may be extremely difficult to diagnose. The symptoms are quite sub-
tle and difficult to distinguish from normal machine operating noise. If there is reason to
believe these components are damaged, remove the components and inspect them.
Inspection notes
1.Investigate any unusual noises.
*********************************
The following “noises” may indicate a
mechanical defect:
a.A “rolling rumble” noise during coasting,
acceleration, or deceleration. The noise
increases with front and/or rear wheel
speed, but it does not increase with
higher engine or transmission speeds.
Diagnosis: Possible wheel bearing dam-
age.
b.A “whining” noise that varies with accel-
eration and deceleration.
Diagnosis: Possible incorrect reassembly,
too-little gear lash.
7-1

CAUTION:
Too little gear lash is extremely destructive to
the gear teeth. If a test ride following reas-
sembly indicates this condition, stop riding
immediately to minimize gear damage.
c.A slight “thunk” evident at low speed
operation. This noise must be distin-
guished from normal machine operation.
Diagnosis: Possible broken gear teeth.
WARNING
Stop riding immediately if broken gear
teeth are suspected. This condition could
result in the shaft drive assembly locking
up, causing loss of control of the machine
and possible injury to the rider.
*********************************
2.Inspect:
● Drained oil
Drained oil shows large amounts of metal

particles → Check the bearing for seizure.
NOTE:
A small amount of metal particles in the oil
is normal.
3.Inspect:
● Oil leakage
*********************************
Oil leakage inspection steps:
● Clean the entire machine thoroughly, then
dry it.
● Apply a leak-localizing compound or dry
powder spray to the shaft drive.
● Road test the machine for the distance
necessary to locate the leak.
Leakage → Inspect the component hous-
ing, gasket, and/or seal for
damage.
Damage → Replace the component.
NOTE:
● An apparent oil leak on a new or nearly
new machine may be the result of a rust-

preventative coating or excessive seal
lubrication.
● Always clean the machine and recheck the
suspected location of an apparent leak-

age.
*********************************
7-2

Troubleshooting Chart
When basic condition “a” and “b” exist, check the following points:
YES
Elevate and spin both wheels. Feel for Replace the wheel bearing.
wheel bearing damage. (Refer to “STEERING SYSTEM” and
“REAR SHOCK ABSORBER AND
SWINGARM” in CHAPTER 8.)
NO
NO
Check the wheel nuts and hub nuts for Torque to specification.
tightness. (Refer to “FRONT AND REAR WHEELS”
in CHAPTER 8.)
YES
NO
Check the constant velocity joint. Feel Constant velocity joint bearings and dif-
for bearing damage. ferential gear bearings are probably not
damaged. Repeat the test or remove the
individual components.
YES
NO
Check the rear brake adjustment. Adjust per instructions.
(Refer to “REAR BRAKE ADJUSTMENT”
in CHAPTER 3.)
YES
NO
Check the rear axle. Feel for bearing Rear axle bearings and rear drive shaft
damage. bearings are probably not damaged.
Repeat the test or remove the individual
components.
YES
Remove the rear axle. Check for axle YES Replace the rear axle bearing.
bearing damage. (Refer to “REAR AXLE/FINAL DRIVE
GEAR AND DRIVE SHAFT”.)
NO
Remove the drive shaft components.
7-3

CONSTANT VELOCITY JOINTS AND DIFFERENTIAL GEAR DRIV
CONSTANT VELOCITY JOINTS AND DIFFERENTIAL GEAR

Constant velocity joint and differen- Remove the parts in the order below.
tial gear removal
Engine skid plate (front) Refer to “SEAT, CARRIERS, FENDERS
Front fender AND FUEL TANK” in CHAPTER 3.
Differential gear oil Drain.
Steering knuckle Refer to “STEERING SYSTEM” in
CHAPTER 8.
Front arms (lower) Refer to “FRONT ARMS AND FRONT
SHOCK ABSORBER” in CHAPTER 8.
1 Constant velocity joint 2
2 Gear motor coupler/four-wheel drive 1/1
switch lead
3 Differential gear case breather hose 1 Disconnect.
7-4


4 Differential gear 1
5 Drive shaft 1
7 Coupling gear 1
procedure.
7-5


Constant velocity joint disassembly Disassemble the parts in the order
below.
1 Circlip 1
2 Boot band 2
3 Boot band 2
4 Dust boot 2
5 Circlip 1 Refer to “CONSTANT VELOCITY
6 Double off-set joint 1 JOINT ASSEMBLY”.
7 Snap ring 1
8 Ball bearing 1
9 Joint shaft assembly 1
procedure.
7-6


Defferential gear disassembly Disassembly the parts in the order
below.
1 Gear motor/O-ring 1/1
2 Four-wheel drive switch 1
3 Dust seal 1
4 Circlip 1
5 Coupling gear/bearing/circlip 1/1/1
6 Stopper bolt/shaft 1/1
7 Shift fork sliding gear 1
8 Shift fork 1
9 2WD/4WD shift sleeve 1
0 Differential gear case cover 1
A Shim (left)
B Differential gear assembly 1
7-7


C Shim (right) 1
D Circlip/bearing 1/1
E Drive pinion gear 1
F Differential gear case 1
procedure.
7-8

RING GEAR REMOVAL
1.Remove:
● Ring gear 1
NOTE:
The ring gear and the differential gear cover
should be fastened together. Do not disas-
semble the differential gear.
CAUTION:
The differential gears are assembled into a
proper unit at the factory by means of spe-
cialized equipment. Do not attempt to dis-
assemble this unit. Disassembly will result
in the malfunction of the unit.
CONSTANT VELOCITY JOINT INSPECTION

1.Inspect:
● Double off-set joint spline
● Ball joint spline
● Shaft spline
2.Inspect:
● Dust boots
CAUTION:
Always use a new boot band.
3.Inspect:
● Balls and ball races
● Inner surface of double off-set joint
Pitting/wear/damage → Replace.
DIFFERENTIAL GEAR INSPECTION

1.Inspect:
● Gear teeth
Pitting/galling/wear → Replace drive pin-

ion gear and ring gear as a set.
● Bearing
Pitting/damage → Replace.
● Oil seal
● O-ring
Damage → Replace.
7-9

2.Inspect:
● Drive shaft splines
● Universal joints
● Front drive gear splines
● Spring
Fatigue → Replace.
Move the spring up and down.
3.Inspect:
● Front drive shaft
Bends → Replace.
WARNING
Do not attempt to straighten a bent shaft;
this may dangerously weaken the shaft.
CONSTANT VELOCITY JOINT ASSEMBLY

1.Apply:
● Molybdenum disulfide grease
(into the ball joint assembly)

NOTE:
Molybdenum disulfide grease is included in
the repair kit.
2.Install:
● Dust boots 1
● Boot bands 2, 3 New
*********************************
Installation steps:
● Apply molybdenum disulfide grease into
the dust boots.
Molybdenum disulfide grease:
40 g (1.4 oz) per dust boot
● Install the dust boots.

● Install the dust boot bands.
NOTE:
● The new boot bands may differ from the
original ones.
● The dust boots should be fastened with
the boot bands 3 at the grooves in the

joint shaft.
*********************************
7 - 10

3.Check:
● Free play (thrust movement)
Excessive play → Replace the joint assem-

bly.
DIFFERENTIAL GEAR ASSEMBLY

1.Measure:
● Gear lash
Refer to “DIFFERENTIAL GEAR LASH

MEASUREMENT AND ADJUSTMENT”.
2.Install:
● Gear motor
Refer to “FEATURES” in CHAPTER 1.
3.Check:
● Differential gear operation
Unsmooth operation → Replace the differ-
ential gear assembly.
Insert the double off-set joint into the dif-
ferential gear, and turn the gear back and
forth.
DIFFERENTIAL GEAR LASH MEASUREMENT

AND ADJUSTMENT
Differential gear lash measurement
1.Secure the gear case in a vise or another
supporting device.
2.Remove:
● Drain plug
● Gasket
3.Install:
● A bolt of the specified size 1
(into the drain plug hole)
CAUTION:
Finger tighten the bolt until it holds the
ring gear. Otherwise, the ring gear will be
damaged.
7 - 11

4.Attach:
● Gear lash measurement tool 1
● Dial gauge 2

P/N. YM-01475, 90890-01475
a Measuring point is 30 mm (1.18 in)

5.Measure:
● Gear lash
Gently rotate the gear coupling from

engagement to engagement.
Differential gear lash:

0.08 ~ 0.39 mm (0.003 ~ 0.015 in)
NOTE:
Measure the gear lash at four positions.
Rotate the shaft 90˚ each time.
Differential gear lash adjustment

1.Remove:
● Shim(s) (left) 1
● Differential gear assembly 2
● Shim(s) (right) 3
2.Adjust:
● Gear lash
*********************************
Gear lash adjustment steps:
● Select the suitable shims using the follow-
ing chart.
Too little gear lash Reduce shim thickness.

Too large gear lash Increase shim thickness.
● If it is necessary to increase by more than
0.05 mm (0.002 in):
Reduce right shim thickness by 0.1 mm
(0.004 in) for every 0.1 mm (0.004 in) of
left shim increase.
● If it is necessary to reduce by more than
0.1 mm (0.004 in):
Increase right shim thickness by 0.1 mm
(0.004 in) for every 0.1 mm of left shim
decreased.
7 - 12

Ring gear shim (left and right)
0.1 1.0
0.2 1.5
0.4 2.5
0.5
DIFFERENTIAL GEAR OPERATION CHECK

1.Block the rear wheels, and elevate the
front wheels by placing a suitable stand
under the frame.
2.Remove the wheel cap and cotter pin
from the axle nut (right or left).
3.Measure the starting torque of the front
wheel (i.e., differential gear preload) with
the torque wrench.
NOTE:
● Repeat this step several times to obtain an
average figure.
● During this test, the other front wheel will
turn in the opposite direction.
Front wheel starting torque

(differential gear preload):
T.
R.
New unit:
17 ~ 25 Nm
(1.7 ~ 2.5 m • kg, 12 ~ 18 ft • lb)
Minimum:
10 Nm (1.0 m • kg, 7.2 ft • lb)
4.Out of specification → Replace the differ-

ential gear assembly.
5.Within specification → Install the new cot-
ter pin and wheel cap.
7 - 13

REAR AXLE/FINAL DRIVE GEAR AND DRIVE SHAFT DRIV
REAR AXLE/FINAL DRIVE GEAR AND DRIVE SHAFT

Rear axle, final drive gear assembly Remove the parts in the order below.
and drive shaft removal
Final gear oil Drain.
Rear wheel hubs/brake disc Refer to “FRONT AND REAR WHEELS”
in CHAPTER 8.
1 O-ring 1
2 Rear axle/dust cover 1/1
3 Trailer hitch bracket 1 Refer to “REAR AXLE
REMOVAL/INSTAL-
4 Final drive gear case breather hose 1 Disconnect. LATION”.
5 Final drive gear 1
6 Coupling gear 1
7 Drive shaft 1
8 Circlip 2
procedure.
7 - 14


Final drive gear disassembly Disassemble the parts in the order
below.
1 Bolt 2 NOTE:
2 Bolt 6 Working in a crisscross pattern, loosen
each bolt 1/4 of a turn. After all the
bolts are loosened, remove them.
3 Bearing housing 1
4 Oil seal/bearing 1/1
5 Ring gear stopper 1
6 Ring gear stopper shim 1
7 Oil seal/bearing 1/1
8 Ring gear shim 1
9 Ring gear 1
0 Thrust washer 1
7 - 15


A Bearing retainer/O-ring 1/1
B Oil seal 1
C Final drive pinion gear 1 Refer to “FINAL DRIVE GEAR DISAS-
D Collar 1 SEMBLY/ASSEMBLY”.
E Bearing 1
F Final drive pinion gear shim 1
G Final drive gear case/O-ring 1/1
H Bearing/oil seal 1/1 Refer to “FINAL DRIVE ROLLER BEAR-
ING REMOVAL AND REASSEMBLY”.
I Bearing 1 Refer to “FINAL DRIVE ROLLER BEAR-
ING REMOVAL AND REASSEMBLY”.
procedure.
7 - 16

REAR AXLE REMOVAL
1.Remove:
● Rear axle 1
(with dust seal)

● O-ring
CAUTION:
● Never directly tap the axle end with a
hammer, since this will result in damage
to the axle thread and spline.
● Attach a suitable socket 2 on the axle
end and tap it with a soft hammer. Pull
out the rear axle to the right.
FINAL DRIVE GEAR DISASSEMBLY

1.Remove:
● Bearing retainer (final drive pinion gear)
NOTE:
Use a bearing retainer wrench 1.

P/N. YM-04050, 90890-04050
CAUTION:
The final drive shaft bearing retainer has
left-handed threads. To loosen the retainer,
turn it clockwise.
2.Remove:
● Final drive pinion gear assembly
With a soft hammer, lightly tap on the

final drive pinion gear end.
CAUTION:
Removal of the final drive pinion gear
should only be performed if gear replace-
ment is necessary.
WARNING
Always use new bearings and races.
7 - 17

FINAL DRIVE ROLLER BEARING REMOVAL
AND REASSEMBLY
1.Remove:
● Roller bearing (ring gear) 1
Use a suitable press tool 2 and an appro-

priate support for the main housing.
● Oil seal 3
2.Remove:
● Roller bearing (final drive pinion gear) 1
*********************************
Removal steps:
● Heat the main housing only to 150 ˚C
(302 ˚F).
● Remove the roller bearing outer race with
an appropriately shaped punch 2.
● Remove the inner race from the final drive
pinion gear.
NOTE:
The removal of the final drive pinion gear
roller bearing is difficult and seldom neces-
sary.
*********************************
3.Install:
● Roller bearing (final drive pinion gear) New
*********************************
Installation steps:
● Heat the main housing only to 150 ˚C
(302 ˚F).
● Install the roller bearing outer race using
the proper adapter.
● Install the inner race onto the drive pinion
gear.
*********************************
4.Install:
● Oil seal 1 New
● Roller bearing 2
Use a suitable press tool 3 and a press to

install the above components into the
main housing.
7 - 18

FINAL DRIVE PINION GEAR AND RING
GEAR POSITIONING
When the final drive pinion gear, ring gear,
final gear case and/or ring gear bearing
housing are replaced, be sure to adjust the
positions of the final drive pinion gear and
ring gear using the shim(s).
Final drive pinion gear shim selection

1.Select:
● Final drive pinion gear shim(s) 1
*********************************
Shim selection steps:
● To find the final drive pinion gear shim
thickness “A”, use the following formula.
Final drive pinion gear shim thickness:

“A” = a – b
a = a numeral (usually a decimal number)

on the final drive pinion gear either
added to or subtracted from “84”
b = a numeral (usually a decimal number)
on the final gear case either added to
or subtracted from “83”
Example:
1) If “01” is stamped on the final drive
pinion gear,
a = 84 + 0.01 = 84.01
2) If “50” is stamped on the final gear
case,
b = 83 + 0.50 = 83.50
3) Therefore, “A” is 0.51.
“A”= 84.01 – 83.50
= 0.51
4) Round off the hundredth digit and
select the appropriate shim(s).
number is 0.51. The chart instructs
you to round off 1 to 0 at the hun-
dredth place. Thus, the shim thick-
ness is 0.50 mm.
Hundredths Rounded value

0, 1, 2 0
3, 4, 5, 6, 7 5
8, 9 10
7 - 19

nesses.
Final drive pinion gear shim
0.15 0.30 0.40

Thickness (mm)
0.45 0.50 0.60
*********************************
Ring gear shim selection

1.Select:
● Ring gear shim(s) 1
*********************************
Shim selection steps:
● To find the ring gear shim thickness “B”,
use the following formula.
Ring gear shim thickness:

“B” = c + d – (e + f)- -
c = a numeral (usually a decimal number)

on the final gear case either added to
or subtracted from 45
d = a numeral (usually a decimal number)
on the outside of the ring gear bear-
ing housing and added to 1
e = a numeral (usually a decimal number)
on the inside of the ring gear either
added to or subtracted from 35.00
f = bearing thickness (considered con-
stant)
Bearing thickness f:
11.00 mm
Example:
1) If “53” is stamped on the final gear
case,
c = 45 + 0.53 = 45.53
2) If “05” is stamped on the ring gear
bearing housing,
d = 1 + 0.05
= 1.05
3) If “–05” is stamped on the ring gear,
e = 35 – 0.05
= 34.95
4) f = 11.00.
7 - 20

5) Therefore, shim thickness “B” is 0.63.
“B”= 45.53 + 1.05 – (34.95 + 11.00)
= 46.58 – 45.95
= 0.63
6) Round off the hundredth digit and
select the appropriate shim(s).
number is 0.63. The chart instructs
you to round off 3 to 5 at the hun-
dredth place.
Thus, the shim thickness is 0.65 mm.
Hundredths Rounded value

0, 1, 2 0
3, 4, 5, 6, 7 5
8, 9 10
nesses.
Ring gear shim
0.25 0.30 0.35

Thickness (mm)
0.40 0.45 0.50
*********************************
Thrust washer selection

1.Measure/select:
● Ring gear thrust clearance “C”
*********************************
Thrust clearance measurement steps:
● Place four pieces of Plastigauge® between
the originally fitted thrust washer and the
ring gear.
● Install the ring gear assembly and tighten
the bolts to specification.
M8 Bolts (bearing housing):
23 Nm (2.3 m • kg, 17 ft • lb)
T.
R.
M10 Bolts (bearing housing):

40 Nm (4.0 m • kg, 29 ft • lb)
NOTE:
Do not turn the drive pinion gear and ring
gear when measuring the clearance with Plas-
tigauge®.
7 - 21

● Remove the ring gear assembly.
● Measure the thrust clearance. Calculate
the width of the flattened Plastigauge® 1.
Ring gear thrust clearance:

0.1 ~ 0.2 mm (0.004 ~ 0.008 in)
● Ifout of specification, select the correct

washer.
Thrust washer selection steps:

● Select a suitable thrust washer using the
following chart.
Thrust washer
1.2 1.3 1.4

1.5 1.6 1.7
Thickness (mm)
1.8 1.9 2.0
2.1
● Repeat the measurement steps until the

ring gear thrust clearance is within the
specified limits.
*********************************
Ring gear stopper shim selection

1.Measure:
● Ring gear stopper clearance “D”
Use a feeler gauge 1.

Ring gear stopper clearance “D”:

0.30 ~ 0.60 mm (0.012 ~ 0.024 in)
2 Ring gear
3 Ring gear stopper
7 - 22

Ring gear stopper clearance adjustment
1.Remove:
● Ring gear 1
● Ring gear stopper 2
● Shim(s) 3
4 Bearing housing
Å Left-hand threads
2.Select:
● Suitable shim(s)
Shim
0.10 0.15 0.20

Thickness (mm)
0.30 0.40 0.50
3.Install:
● Shim(s)
● Ring gear stopper (left-hand threads)
9 Nm (0.9 m • kg, 6.5 ft • lb)

T.
R.
● Ring gear
NOTE:
Use LOCTITE on the ring gear stopper.
4.Measure:
● Ring gear stopper clearance
Out of specification → Repeat adjustment

steps.
Ring gear stopper clearance:

0.30 ~ 0.60 mm (0.012 ~ 0.024 in)
REAR AXLE INSPECTION

1.Inspect:
● Rear axle runout a
WARNING
Do not attempt to straighten a bent axle.
Rear axle runout limit:

1.5 mm (0.06 in)
7 - 23

DRIVE SHAFT INSPECTION
1.Inspect:
● Drive shaft (splines) 1
● Coupling gear (splines) 2
FINAL DRIVE GEAR INSPECTION

1.Inspect:
● Final gear case 1
● Bearing housing (ring gear) 2
NOTE:
When the final gear case and/or the ring
gear bearing housing are replaced, be sure
to adjust the shim of the final drive pinion
gear and/or ring gear.
2.Inspect:
● Gear teeth
Pitting/galling/wear → Replace the drive

pinion gear and ring gear as a set.
● Oil seals
● O-rings
Damage → Replace.
3.Inspect:
● Bearings
Damage → Replace.
NOTE:
● Reusing roller bearings is acceptable, but
Yamaha recommends installing new

ones. Do not reuse the oil seal.
● When the final drive pinion gear and/or
ring gear are replaced, be sure to adjust

the shim of the final drive pinion gear and/
or ring gear.
7 - 24

FINAL GEAR LASH MEASUREMENT AND
ADJUSTMENT
Final gear lash measurement
1.Secure the gear case in a vise or another
supporting device.
2.Remove:
● Drain plug
● Gasket
3.Install:
● A bolt of the specified size 1
(into the drain plug hole)
CAUTION:
Finger tighten the bolt until it holds the
ring gear. Otherwise, the ring gear will be
damaged.
4.Attach:
● Gear lash measurement tool 1
● Dial gauge 2

P/N. YM-01231, 90890-01231
a Measuring point is 27 mm (1.06 in)
5.Measure:
● Gear lash
Gently rotate the gear coupling from

engagement to engagement.
Final gear lash:

0.1 ~ 0.2 mm (0.004 ~ 0.008 in)
NOTE:
Measure the gear lash at four positions.
Rotate the shaft 90˚ each time.
7 - 25

Final gear lash adjustment
1.Remove:
● Bearing housing 1
● Ring gear shim(s) 2
● Ring gear 3
● Thrust washer 4
2.Adjust:
● Gear lash
*********************************
Adjustment steps:
● Select a suitable shim(s) and thrust
washer(s) using the following chart.
Too little gear lash Reduce shim thickness.
Too large gear lash Increase shim thickness.
● If increased by more than 0.2 mm (0.008

in):
Reduce the thrust washer thickness by 0.2
mm (0.008 in) for every 0.2 mm of ring
gear shim increase.
● If reduced by more than 0.2 mm (0.008 in):
Increase the thrust washer thickness by
0.2 mm (0.008 in) for every 0.2 mm that
the ring gear shim is decreased.
Ring gear shim
0.25 0.30 0.35

Thickness (mm)
0.40 0.45 0.50
Thrust washer
1.2 1.3 1.4

1.5 1.6 1.7
Thickness (mm)
1.8 1.9 2.0
2.1
*********************************
7 - 26

FINAL DRIVE GEAR ASSEMBLY
1.Install:
● Drive pinion gear (with shim(s) and bear-
ing)
(proper shim size as calculated)
● Bearing retainer (drive pinion gear) 1
100 Nm (10.0 m • kg, 72 ft • lb)
T.
R.
Use a bearing retainer wrench 2.
CAUTION:
● Always use a new bearing.
● The final drive shaft bearing retainer has
left-hand threads. Turn the retainer coun-
terclockwise to tighten it.

P/N. YM-04050, 90890-04050
2.Adjust:
● Final gear lash
Refer to “FINAL GEAR LASH MEASURE-
MENT AND ADJUSTMENT”.
FINAL DRIVE GEAR INSTALLATION

1.Lubricate:
● Drive shaft
● Coupling gear
● O-ring
● Oil seal
● Bearing
Lithium-soap base grease
2.Install:
● Drive shaft 1
● Coupling gear 2
(to the universal joint)
7 - 27

3.Apply:
● Sealant (Quick Gasket )
®
(to the mating surfaces of the swingarm

and the final drive gear case)
Sealant (Quick gasket®):

P/N. ACC-11001-05-01
Yamaha bond No.1215®:
P/N. 90890-85505
4.Install:
● Final drive gear
● Nuts LT 57 Nm (5.7 m • kg, 41 ft • lb)
T.
R.
● Bolts LT 63 Nm (6.3 m • kg, 45 ft • lb)
T.
R.
7 - 28

CHAS
8
CHAS
CHAPTER 8.
CHASSIS
FRONT AND REAR WHEELS .......................................................................8-1

FRONT WHEELS ...................................................................................8-1
REAR WHEELS ......................................................................................8-2
WHEEL INSPECTION ............................................................................8-3
WHEEL HUB INSPECTION ...................................................................8-3
BRAKE DISC INSPECTION ...................................................................8-4
WHEEL HUB/BRAKE DRUM INSTALLATION .....................................8-4
WHEEL INSTALLATION .......................................................................8-4
FRONT AND REAR BRAKES ........................................................................8-6

FRONT BRAKE PADS ...........................................................................8-6
REAR BRAKE PADS ..............................................................................8-7
FRONT BRAKE PAD REPLACEMENT ..................................................8-8
REAR BRAKE PAD REPLACEMENT ...................................................8-10
FRONT BRAKE MASTER CYLINDER .................................................8-12
REAR BRAKE MASTER CYLINDER ....................................................8-14
MASTER CYLINDER INSPECTION ....................................................8-17
FRONT BRAKE MASTER CYLINDER ASSEMBLY ............................8-18
REAR BRAKE MASTER CYLINDER ASSEMBLY ...............................8-18
FRONT BRAKE MASTER CYLINDER INSTALLATION ......................8-19
REAR BRAKE MASTER CYLINDER INSTALLATION ........................8-20
FRONT BRAKE CALIPER ....................................................................8-22
REAR BRAKE CALIPER .......................................................................8-24
FRONT AND REAR BRAKE CALIPER DISASSEMBLY ......................8-26
FRONT AND REAR BRAKE CALIPER INSPECTION ..........................8-26
FRONT AND REAR BRAKE CALIPER ASSEMBLY ............................8-27
FRONT BRAKE CALIPER INSTALLATION .........................................8-27
REAR BRAKE CALIPER INSTALLATION ...........................................8-29
STEERING SYSTEM ...................................................................................8-30

HANDLEBAR .......................................................................................8-30
REAR BRAKE SWITCH REMOVAL .....................................................8-32
HANDLEBAR INSPECTION ................................................................8-32
HANDLEBAR INSTALLATION ............................................................8-32
REAR BRAKE LEVER INSTALLATION ...............................................8-32
MASTER CYLINDER ASSEMBLY INSTALLATION ...........................8-33
STEERING STEM ................................................................................8-34
BEARING RETAINER REMOVAL .......................................................8-36
STEERING STEM INSPECTION .........................................................8-36
BEARING RETAINER INSTALLATION ...............................................8-36
CABLE GUIDE INSTALLATION ..........................................................8-36
TIE ROD AND STEERING KNUCKLE .................................................8-37
STEERING KNUCKLE REMOVAL ......................................................8-38
TIE ROD INSPECTION ........................................................................8-38

CHAS
STEERING KNUCKLE INSPECTION ..................................................8-38
BALL JOINT INSPECTION ..................................................................8-39
TIE ROD INSTALLATION ....................................................................8-39
FRONT ARMS AND FRONT SHOCK ABSORBER .....................................8-40

FRONT ARMS REMOVAL ..................................................................8-42
FRONT ARM INSPECTION .................................................................8-42
FRONT SHOCK ABSORBER INSPECTION ........................................8-42
FRONT ARMS AND
FRONT SHOCK ABSORBER INSTALLATION ................................8-43
REAR SHOCK ABSORBER AND SWINGARM ..........................................8-44

SWINGARM REMOVAL .....................................................................8-45
REAR SHOCK ABSORBER INSPECTION ...........................................8-45
SWINGARM INSPECTION .................................................................8-46
RUBBER BOOT INSPECTION .............................................................8-46
RUBBER BOOT INSTALLATION ........................................................8-46

FRONT AND REAR WHEELS CHAS
CHASSIS
FRONT AND REAR WHEELS
FRONT WHEELS

Front wheel removal Remove the parts in the order below.
Place the machine on a level surface.
WARNING
Securely support the machine so
there is no danger of it falling over.
1 Front wheel 1 Refer to “WHEEL INSTALLATION”.
2 Wheel cap 1
Refer to “WHEEL HUB/BRAKE DRUM
3 Cotter pin 1
INSTALLATION”.
4 Axle nut 1
5 Brake caliper assembly 1 NOTE:
Do not squeeze the brake lever when
the brake caliper is off of the brake disc
as the brake pads will be forced shut.
6 Wheel hub 1
7 Brake disc 1
procedure.
8-1

REAR WHEELS

Rear wheel removal Remove the parts in the order below.
Place the machine on a level surface.
WARNING
Securely support the machine so
there is no danger of it falling over.
1 Rear wheel 2 Refer to “WHEEL INSTALLATION”.
2 Wheel cap 2
Refer to “WHEEL HUB/BRAKE DRUM
3 Cotter pin 2
INSTALLATION”.
4 Axle nut 2
5 Wheel hub 2
6 Brake caliper mounting bolt 2
7 Brake disc bracket 1
8 Brake disc 1
procedure.
8-2

WHEEL INSPECTION
1.Inspect:
● Wheel
2.Measure:
● Wheel runout
Over the specified limit → Replace the

wheel or check the wheel bearing play 1.
Wheel runout limit:

Radial 2: 2.0 mm (0.08 in)
Lateral 3: 2.0 mm (0.08 in)
3.Check:
● Wheel balance
Out of balance → Adjust.
WARNING
After replacing the tire, ride conservatively
to allow the tire to be properly seated in
the rim. Failure to do so may cause an acci-
dent resulting in machine damage and pos-
sible operator injury.
WHEEL HUB INSPECTION

1.Inspect:
● Wheel hub 1
● Splines (wheel hub) 2
8-3

BRAKE DISC INSPECTION
1.Inspect:
● Brake disc
Galling/damage → Replace.
2.Measure:
● Brake disc deflection
Out of specification → Inspect the wheel

runout.
If wheel runout is within the limits,
replace the brake disc.
Brake disc maximum deflection:

0.15 mm (0.006 in)
● Brake disc thickness a

Brake disc minimum thickness:

3 mm (0.12 in)
WHEEL HUB/BRAKE DRUM INSTALLATION

1.Install:
● Cotter pin 1 New
NOTE:
Do not loosen the axle nut after torquing it.
If the axle nut groove is not aligned with the
cotter pin hole, align the groove with the
hole by tightening the axle nut.
2.Adjust:
● Front brake lever free play
Refer to “FRONT BRAKE ADJUSTMENT”
in CHAPTER 3.
● Rear brake lever and pedal free play
Refer to “REAR BRAKE LEVER AND

PEDAL ADJUSTMENT” in CHAPTER 3.
WHEEL INSTALLATION
1.Install:
● Wheel
NOTE:
The arrow mark 1 on the tire must point in
the direction of rotation Å of the wheel.
8-4

2.Tighten:
● Nuts (wheel) 1
WARNING
Tapered wheel nuts 1 are used for both
the front and rear wheels. Install each nut
with its tapered side towards the wheel.
8-5

FRONT AND REAR BRAKES CHAS
FRONT AND REAR BRAKES
FRONT BRAKE PADS

Front brake pads removal Remove the parts in the order below.
Front wheel Refer to “FRONT AND REAR
WHEELS”.
2 Brake pad holding bolt 2 Refer to “FRONT BRAKE PAD
3 Brake pad/pad shim 2/1 REPLACEMENT”.
4 Pad spring 1
procedure.
8-6

REAR BRAKE PADS

Rear brake pads removal Remove the parts in the order below.
Rear wheel (left) Refer to “FRONT AND REAR
WHEELS”.
2 Brake pad holding bolt 2 Refer to “REAR BRAKE PAD
3 Brake pad/insulator/pad shim 2/2/2 REPLACEMENT”.
4 Pad spring 1
procedure.
8-7

CAUTION:
Disc brake components rarely require dis-
assembly. DO NOT:
● disassemble components unless abso-
lutely necessary;
● use solvents on internal brake compo-
nents;
● use spent brake fluid for cleaning; (use
only clean brake fluid)

● allow brake fluid to come in contact with
the eyes, as this may cause eye injury;

● splash brake fluid onto painted surfaces or
plastic parts, as this may cause damage;

● disconnect any hydraulic connection, as
this would require the entire brake sys-

tem to be disassembled, drained,
cleaned, properly filled and bled after
reassembly.
FRONT BRAKE PAD REPLACEMENT

NOTE:
It is not necessary to disassemble the brake
caliper and brake hose to replace the brake
pads.
1.Measure:
● Brake pad wear limit a
Out of specification → Replace the brake

pad as a set.
Brake pad wear limit:

1 mm (0.04 in)
2.Install:
● Brake pads
● Brake pad spring
NOTE:
Always install new brake pads, brake pad
shim and brake pad spring as a set.
8-8

*********************************
Installation steps:
● Connect a suitable hose 1 tightly to the
brake caliper bleed screw 2. Put the other
end of this hose into an open container.
● Loosen the brake caliper bleed screw and,
using a finger, push the caliper piston into
the brake caliper.
● Tighten the brake caliper bleed screw.
Brake caliper bleed screw:

6 Nm (0.6 m • kg, 4.3 ft • lb)
T.
R.
● Install new brake pads, new pad shims 3
and a new brake pad spring.
● Install the retaining bolts and brake cali-
per.
NOTE:
The arrow mark a on the pad shim must
point in the direction of the disc rotation.
Brake pad holding bolt:

18 Nm (1.8 m • kg, 13 ft • lb)
T.
R.
Brake caliper mounting bolt:

30 Nm (3.0 m • kg, 22 ft • lb)
*********************************
3.Inspect:

TION” in CHAPTER 3.
4.Check:
● Brake lever operation
Soft or spongy feeling → Bleed the front

brake system.
BRAKE SYSTEM)” in CHAPTER 3.
8-9

REAR BRAKE PAD REPLACEMENT
NOTE:
It is not necessary to disassemble the brake
caliper and brake hose to replace the brake
pads.
1.Measure:
● Brake pad wear limit a
Out of specification → Replace the brake

pad as a set.
Brake pad wear limit:

1 mm (0.04 in)
2.Install:
● Brake pads
● Brake pad spring
NOTE:
Always install new brake pads, brake pad
shims, insulator and brake pad spring as a
set.
*********************************
Installation steps:
● Connect a suitable hose 1 tightly to the
brake caliper bleed screw 2. Put the other
end of this hose into an open container.
● Loosen the brake caliper bleed screw and,
using a finger, push the caliper piston into
the brake caliper.
● Tighten the brake caliper bleed screw.
Brake caliper bleed screw:

6 Nm (0.6 m • kg, 4.3 ft • lb)
T.
R.
● Install new brake pads, new insulator,

new pad shims and a new brake pad
spring.
● Install the retaining bolts and brake cali-
per.
Brake pad holding bolt:
18 Nm (1.8 m • kg, 13 ft • lb)
T.
R.
Brake caliper mounting bolt:

30 Nm (3.0 m • kg, 22 ft • lb)
8 - 10 *********************************

3.Inspect:

4.Check:
● Brake lever or brake pedal operation
Soft or spongy feeling → Bleed the rear

brake system.
8 - 11

FRONT BRAKE MASTER CYLINDER

Front brake master cylinder removal Remove the parts in the order below.
Brake fluid Drain.
1 Brake fluid reservoir cap 1
2 Brake fluid reservoir diaphragm 1
holder
4 Brake lever 1
5 Union bolt 1
6 Copper washer 2
Refer to “FRONT BRAKE MASTER
7 Brake hose 1
CYLINDER INSTALLATION”.
8 Brake master cylinder bracket 1
9 Brake master cylinder 1
procedure.
8 - 12


Front brake master cylinder disas- Disassemble the parts in the order
sembly below.
1 Dust boot 1
Refer to “FRONT BRAKE MASTER
2 Circlip 1
CYLINDER ASSEMBLY”.
3 Brake master cylinder kit 1
procedure.
8 - 13

REAR BRAKE MASTER CYLINDER

Rear brake master cylinder removal Remove the parts in the order below.
Front fender panel Refer to “SEAT, CARRIERS, FINDERS
Brake fluid Drain.
1 Brake fluid reservoir cap 1
holder
4 Brake fluid reservoir 1
5 Brake master cylinder cover 1
6 Brake fluid reservoir hose 1
7 Hose joint 1
8 - 14


8 Union bolt 1
9 Copper washer 2 Refer to “REAR BRAKE MASTER CYL-
10 Brake hose 1 INDER INSTALLATION”.
11 Brake master cylinder 1
procedure.
8 - 15


Front brake master cylinder disas- Disassemble the parts in the order
sembly below.
1 Brake master cylinder kit 1 Refer to “REAR BRAKE MASTER CYL-
2 Brake master cylinder 1 INDER ASSEMBLY”.
procedure.
8 - 16

Å MASTER CYLINDER INSPECTION
1.Inspect:
● Brake master cylinder 1
Wear/scratches → Replace the brake mas-

ter cylinder assembly.
● Brake master cylinder body
● Brake fluid delivery passage
(brake master cylinder body)

Blockage → Blow out with compressed
ı air.
Å Front
ı Rear
Å ı 2.Inspect:
● Brake master cylinder kit
Scratches/wear/damage → Replace as a
set.
Å Front
ı Rear
3.Inspect:
● Front brake master cylinder reservoir 1
● Front brake master cylinder reservoir dia-
phragm 2
4.Inspect:
● Rear brake fluid reservoir 1
● Rear brake fluid reservoir diaphragm 2
8 - 17

EB702060
ASSEMBLY
WARNING
● All internal brake components should be
cleaned and lubricated with new brake
fluid only before installation.

DOT 4
● Whenever a master cylinder is disassem-

bled, replace the piston seals and dust
seals.
EB702060
ASSEMBLY
WARNING

DOT 4
● Whenever a master cylinder is disassem-

bled, replace the piston seals and dust
seals.
1.Install:
● Brake master cylinder kit
● Nut 1
● Joint 2
NOTE:
Turn the adjusting bolt 3 until the clear-
ance a is within the specified limits when
install the joint 2.
Clearance a:
1 ~ 2 mm (0.04 ~ 0.08 in)
2.Tighten:
● Nut 2
8 - 18

INSTALLATION
1.Install:
● Brake master cylinder 1
7 Nm (0.7 m • kg, 5.1 ft • lb)
T.
R.
NOTE:
The “UP” mark on the brake master cylin-
der bracket should face up.
2.Install:
● Copper washers New
● Brake hose
● Union bolt 27 Nm (2.7 m • kg, 19 ft • lb)
T.
R.
NOTE:
● Tighten the union bolt while holding the
brake hose as shown.

● Turn the handlebar to the left and to the
right to check that the brake hose does not

touch other parts (throttle cable, wire har-
ness, leads, etc.). Correct if necessary.
WARNING
Proper brake hose routing is essential to
insure safe machine operation. Refer to
“CABLE ROUTING”.
3.Fill:
● Brake fluid reservoir

DOT 4
CAUTION:
Brake fluid may damage painted surfaces
or plastic parts. Always clean up spilled
brake fluid immediately.
WARNING
● Use only the designated quality brake
fluid: other brake fluids may deteriorate
the rubber seals, causing leakage and
poor brake performance.
● Refill with the same type of brake fluid:
mixing brake fluids may result in a harm-
ful chemical reaction and lead to poor
brake performance.
8 - 19

brake master cylinder when refilling.
Water will significantly lower the boiling
point of the brake fluid and may result in
vapor lock.
4.Air bleed:
● Brake system

5.Inspect:
Brake fluid level is under the “LOWER”

level line → Fill up.

INSTALLATION
1.Install:
● Copper washers 1 New
● Brake hose 2
● Union bolt 3 30 Nm (3.0 m • kg, 22 ft • lb)

T.
R.
CAUTION:
When installing the brake hose onto the
brake master cylinder, make sure the brake
pipe touches the projection a as shown.
WARNING
insure safe machine operation. Refer to
8 - 20

2.Fill:
● Brake fluid reservoir

DOT 4
CAUTION:
WARNING
brake performance.
brake master cylinder when refilling.
Water will significantly lower the boiling
point of the brake fluid and may result in
vapor lock.
3.Air bleed:
● Brake system

4.Inspect:

8 - 21

FRONT BRAKE CALIPER

Front brake caliper removal Remove the parts in the order below.
Brake fluid Drain.
Front wheel Refer to “FRONT AND REAR
WHEELS”.
1 Union bolt 1
2 Copper washer 2
3 Brake hose 1 Disconnect. Refer to “FRONT BRAKE
4 Cap/retaining bolt 1/1 Loosen. CALIPER INSTALLA-
5 Brake pad holding bolt 2 Loosen. TION”.
7 Brake caliper assembly 1
procedure.
8 - 22


Front brake caliper disassembly Disassemble the parts in the order
below.
1 Brake pad holding bolt 2
2 Brake pad/pad shim 2/1
3 Pad spring 1
4 Retaining bolt 1
5 Caliper bracket 1
6 Brake caliper piston 1 Refer to “FRONT AND REAR BRAKE
7 Dust seal 1 CALIPER DISASSEMBLY/ASSEM-
8 Caliper piston seal 1 BLY”.
9 Bleed screw 1
procedure.
8 - 23

REAR BRAKE CALIPER

Rear brake caliper removal Remove the parts in the order below.
Brake fluid Drain.
Rear wheel Refer to “FRONT AND REAR
WHEELS”.
1 Union bolt 1
2 Copper washer 2
Refer to “REAR BRAKE
3 Brake hose 1 Disconnect.
CALIPER INSTALLA-
4 Brake pad holding bolt 2 Loosen.
TION”.
6 Brake caliper assembly 1
procedure.
8 - 24


Rear brake caliper disassembly Disassemble the parts in the order
below.
1 Brake pad holding bolt 2
2 Brake pad/insulator/pad shim 2/2/2
3 Pad spring 1
4 Caliper bracket 1
5 Brake caliper piston 1 Refer to “FRONT AND REAR BRAKE
6 Dust seal 1 CALIPER DISASSEMBLY/ASSEM-
7 Caliper piston seal 1 BLY”.
8 Bleed screw 1
procedure.
8 - 25

FRONT AND REAR BRAKE CALIPER
DISASSEMBLY
1.Remove:
● Brake caliper piston
● Dust seal 1
● Caliper piston seal 2
*********************************
Removal steps:
● Blow compressed air into the hose joint
opening to force out the caliper piston
from the brake caliper body.
WARNING
● Never try to pry out the caliper piston.
● Cover the caliper piston with a rag. Be
careful not to get injured when the piston
is expelled from the master cylinder.
● Remove the caliper piston seals.
*********************************
EB702040
INSPECTION
Recommended brake component replace-
ment schedule:
Brake pads As required
Piston seal, dust seal Every two years
Brake hoses Every two years
Replace when
Brake fluid brakes are disassem-
bled.
WARNING
All internal brake components should be
cleaned in new brake fluid only. Do not use
solvents as they will cause seals to swell
and distort.
Å 1.Inspect:
● Brake caliper piston 1
Scratches/rust/wear → Replace the brake

caliper assembly.
● Brake caliper cylinder 2
Wear/scratches → Replace the brake cali-

per assembly.
● Brake caliper body 3
8 - 26

ı ● Brake fluid delivery passage (brake caliper
body)
Blockage → Blow out with compressed air.
WARNING
Replace the caliper piston seal and dust
seal whenever the brake caliper is disas-
sembled.
Å Front
ı Rear
ASSEMBLY
WARNING

DOT 4
● Replace the caliper piston seal whenever

a brake caliper is disassembled.
1.Install:
● Caliper piston seal 1 New
● Dust seal 2 New
2.Install:
● Brake caliper piston 1
FRONT BRAKE CALIPER INSTALLATION

1.Install:
● Brake caliper assembly
● Brake caliper mounting bolt 1
30 Nm (3.0 m • kg, 22 ft • lb)

T.
R.
● Brake hose 2
T.
R.
8 - 27

CAUTION:
When installing the brake hose on the
brake caliper, make sure that the brake
pipe touches the projection a on the brake
caliper.
WARNING
insure safe motorcycle operation. Refer to
2.Fill:
● Brake reservoir

DOT 4
CAUTION:
WARNING
brake performance.
brake fluid and may result in vapor lock.
3.Air bleed
● Brake system
4.Inspect:

8 - 28

REAR BRAKE CALIPER INSTALLATION
1.Install:
● Brake caliper assembly
● Brake caliper mounting bolt 1
30 Nm (3.0 m • kg, 22 ft • lb)
T.
R.
● Brake hose 2
T.
R.
2.Fill:
● Brake reservoir

DOT 4
CAUTION:
WARNING
brake performance.
brake fluid and may result in vapor lock.
3.Air bleed
● Brake system
4.Inspect:

8 - 29

STEERING SYSTEM CHAS
STEERING SYSTEM
HANDLEBAR

Handlebar removal Remove the parts in the order below.
1 Handlebar cover 1
2 Band 4
3 Master cylinder assembly/bracket 1/1
Refer to “MASTER CYLINDER
4 On command four-wheel drive switch 1
ASSEMBLY INSTALLATION”.
5 Throttle lever assembly/bracket 1/1
6 Rear brake switch 1 Refer to “REAR BRAKE SWITCH
REMOVAL”.
7 Rear brake lever/bracket 1/1 Refer to “REAR BRAKE LEVER
8 Handlebar switch 1 INSTALLATION”.
9 Horn switch 1 For GB, F, CH, Oceania
10 Handlebar grip 2
8 - 30


11 Handlebar holder 2 Refer to “HANDLEBAR INSTALLA-
TION”.
12 Handlebar 1 Refer to “HANDLEBAR INSTALLA-
TION”.
procedure.
8 - 31

REAR BRAKE SWITCH REMOVAL
1.Remove:
● Rear brake switch 1
NOTE:
Push the fastener when removing the rear
brake switch out of the rear brake lever
holder.
HANDLEBAR INSPECTION
1.Inspect:
● Handlebar
Bends/cracks/damage → Replace.
WARNING
Do not attempt to straighten a bent han-
dlebar as this may dangerously weaken the
handlebar.
HANDLEBAR INSTALLATION
1.Install:
● Handlebar
● Handlebar holders
T.
R.
20 Nm (2.0 m • kg, 14 ft • lb)
NOTE:
The upper handlebar holder should be
installed with the punched mark 1 forward
2.
CAUTION:
First tighten the bolts 3 on the front side
of the handlebar holder, and then tighten
the bolts 4 on the rear side.
REAR BRAKE LEVER INSTALLATION

1.Install:
● Handlebar switch 1
● Rear brake lever
● Lever bracket 2
NOTE:
Install the lever bracket as shown.
a 80 mm (3.1 in)
8 - 32

MASTER CYLINDER ASSEMBLY
INSTALLATION
1.Install:
● Throttle lever assembly
● Master cylinder assembly
7 Nm (0.7 m • kg, 5.1 ft • lb)
T.
R.
NOTE:
The “UP” mark on the master cylinder
bracket should face up.
8 - 33

STEERING STEM

Steering removal Remove the parts in the order below.
Handlebar Refer to “HANDLEBAR”.
Seat Refer to “SEAT, CARRIERS, FENDERS
1 Lock washer 1 Refer to “CABLE GUIDE INSTALLA-
2 Cable guide 1 TION”.
3 Steering stem bushing 2
4 Collar 2
5 Oil seal 2
6 Tie rod end nut 2
7 Tie rod 2 Disconnect.
8 Steering stem nut 1
9 Pitman arm 1
10 Steering stem 1
8 - 34


11 Oil seal 1
12 Bearing retainer 1 Refer to “BEARING RETAINER
13 Bearing 1
14 Oil seal 1
procedure.
8 - 35

BEARING RETAINER REMOVAL
1.Remove:
● Bearing retainer (steering stem)
Damper rod holder:

P/N. YM-01327, 90890-01327
STEERING STEM INSPECTION

1.Inspect:
● Steering stem
Bends → Replace.
WARNING
Do not attempt to straighten a bent stem;
this may dangerously weaken the stem.
2.Inspect:
● Oil seals 1
● Steering stem bushings 2
BEARING RETAINER INSTALLATION

1.Install:
● Bearing retainer (steering stem)
40 Nm (4.0 m • kg, 29 ft • lb)

T.
R.
Damper rod holder:

P/N. YM-01327, 90890-01327
CABLE GUIDE INSTALLATION

1.Install
● Cable guide
● Lock washer New

23 Nm (2.3 m • kg, 17 ft • lb)
T.
R.
2.Bend the lock washer tab along a flat side

of the bolt.
NOTE:
Pass the cables and hoses through the
cable guide. Refer to “CABLE ROUTING” in
CHAPTER 2.
8 - 36

TIE ROD AND STEERING KNUCKLE

Tie rod and steering knuckle removal Remove the parts in the order below.
Front fender Refer to “SEAT, CARRIERS, FENDERS
Front wheel/brake disc Refer to “FRONT AND REAR
WHEELS”.
1 Tie rod 1 Refer to “TIE ROD INSTALLATION”.
2 Brake disc guard 1
3 Brake hose holder bolt 1
4 Protector 1
5 Bolt/washer/nut 1/1/1
6 Nut 1
7 O-ring 1
8 Steering knuckle 1 Refer to “STEERING KNUCKLE
REMOVAL”.
procedure.
8 - 37

STEERING KNUCKLE REMOVAL
1.Remove:
● Steering knuckle 1
NOTE:
Use a general puller to separate the ball
joint 2 and steering knuckle.
TIE ROD INSPECTION

1.Check:
● Tie rod free play and movement
Free play → Replace the tie rod end.

Turns roughly → Replace the tie rod end.
2.Inspect:
● Tie rod
● Bends/damage → Replace.
STEERING KNUCKLE INSPECTION

1.Inspect:
● Steering knuckle
Damage/pitting → Replace.
2.Inspect:
● Front wheel bearings
Bearings allow play in the wheel hubs or

the wheel turns roughly → Replace.
● Oil seals
Damage → Replace.
*********************************
Front wheel bearing replacement steps:
● Clean the outside of the steering knuckle.
● Remove the oil seals 1.
● Drive out the bearings 2.
WARNING
Eye protection is recommended when
using striking tools.
● Remove the spacer 3.
● Apply lithium base grease to the bearings
and oil seals.
● Install the spacer to the steering knuckle.
8 - 38

● Install the new bearings.
NOTE:
Install the outside bearing first.
CAUTION:
Do not strike the center race or balls of the
bearing. Contact should be made only with
the outer race.
● Install a new oil seal.
NOTE:
When installing the oil seals, the “seal side”
of the oil seal faces out.
*********************************
BALL JOINT INSPECTION

1.Inspect:
● Ball joint
Damage/pitting → Replace the front arm.

Free play → Replace the front arm.
Turns roughly → Replace the front arm.
TIE ROD INSTALLATION

1.Install:
● Tie rods (left and right)
25 Nm (2.5 m • kg, 18 ft • lb)

T.
R.
NOTE:
The tie rod which must be installed on the
out side has grooves 1.
2.Adjust:
● Toe-in
Refer to “TOE-IN ADJUSTMENT” in

CHAPTER 3.
8 - 39

FRONT ARMS AND FRONT SHOCK ABSORBER CHAS
FRONT ARMS AND FRONT SHOCK ABSORBER

Front arms and front shock absorber Remove the parts in the order below.
removal
Engine skid plate (front) Refer to “SEAT, CARRIERS, FENDERS
Front wheel/brake disc Refer to “FRONT AND REAR WHEELS”.
1 Air duct 1
2 Brake disc guard 1
3 Protector 1
8 - 40


4 Bolt 1
5 Nut 1
6 Bolt/nut 2/2
Refer to “FRONT ARMS REMOVAL”
7 Front arm (lower)/bushing 1/2
and “FRONT ARMS AND FRONT
8 Nut/bolt 2/2
SHOCK ABSORBER INSTALLATION”.
9 Front shock absorber/collar 1/1
10 Bolt/nut 2/2
11 Front arm (upper)/bushing 1/2
procedure.
8 - 41

FRONT ARMS REMOVAL
1.Check:
● Front arm free play
*********************************
Checking steps:
● Check the front arm side play Å by mov-
ing it from side to side.
If side play is noticeable, check the bush-
ings.
● Check the front arm vertical movement ı
by moving it up and down.
If the vertical movement is tight or rough,
or if there is binding, check the bushings.
*********************************
2.Remove:
● Front arms
FRONT ARM INSPECTION

1.Inspect:
● Front arms 1
Bends/damage → Replace.
2.Inspect:
● Bushings 2
FRONT SHOCK ABSORBER INSPECTION

1.Inspect:
● Shock absorber rod
Bends/damage → Replace the shock

absorber assembly.
● Shock absorber assembly
Oil leaks → Replace the shock absorber

assembly.
● Spring
Fatigue → Replace the shock absorber

assembly.
8 - 42

FRONT ARMS AND FRONT SHOCK
ABSORBER INSTALLATION
1.Install:
● Front arms
● Front shock absorber
*********************************
Installation steps:
● Install the front arm (upper) 1 and front
arm (lower) 2.
NOTE:
● Lubricate the bolts 3 with lithium soap
base grease.
● Be sure to position the bolts 3 so that the
bolt head faces outward.

● Temporarily tighten the nuts 4.
● Install the front shock absorber 5.
Nut 6:
45 Nm (4.5 m • kg, 32 ft • lb)
T.
R.
● Install the ball joints.
Nut 7:
25 Nm (2.5 m • kg, 18 ft • lb)
T.
R.
Nut 8:
48 Nm (4.8 m • kg, 35 ft • lb)
● Install
the new cotter pins.
● Tighten the nuts 4.
NOTE:
Before tightening the nuts 4, adjust the
length a to 318 mm (12.5 in).
Nut 4:
45 Nm (4.5 m • kg, 32 ft • lb)
T.
R.
*********************************
8 - 43

REAR SHOCK ABSORBER AND SWINGARM CHAS
REAR SHOCK ABSORBER AND SWINGARM

Rear shock absorber and swingarm Remove the parts in the order below.
removal
Rear wheel hubs/brake disc Refer to “FRONT AND REAR WHEELS”.
Final drive gear assembly Refer to “REAR AXLE/FINAL DRIVE GEAR
AND DRIVE SHAFT” in CHAPTER 7.
1 Clip/washer/pin 1/1/1
2 Nut/bolt 1/1
3 Rear shock absorber 1
4 Collar 2
5 Rear brake hose 1
6 Final drive gear case breather hose 1
7 Metal clamp 1
8 Nut/bolt 2/2
9 Swingarm/bushing 1/2 Refer to “SWINGRAM REMOVAL”.
10 Spring/rubber boot 1/1
procedure.
8 - 44

SWINGARM REMOVAL
1.Inspect:
● Swingarm free play
*********************************
Inspection steps:
● Check the tightening torque of the nuts
(swingarm).
Nut (swingarm):
59 Nm (5.9 m • kg, 43 ft • lb)
T.
R.
● Check the swingarm side play Å by mov-
ing it from side to side.
If side play is noticeable, check the bush-
ing and frame pivot.
● Check the swingarm vertical movement ı
by moving it up and down.
If vertical movement is tight or rough, or if
there is binding, check the bushing and
frame pivot.
*********************************
2.Remove:
● Nuts
● Bolts
● Swingarm
REAR SHOCK ABSORBER INSPECTION

1.Inspect:
● Shock absorber
Oil leaks → Replace the shock absorber

assembly.
● Shock absorber rod
Bends/damage → Replace the shock

absorber assembly.
● Spring
Fatigue → Replace the shock absorber

assembly.
8 - 45

SWINGARM INSPECTION
1.Inspect:
● Swingarm
Bends/cracks/damage → Replace.
2.Inspect:
● Bushings 1
RUBBER BOOT INSPECTION

1.Inspect:
● Rubber boot 1
Damage → Replace.
RUBBER BOOT INSTALLATION

1.Apply:
● Adhesive (for rubber)
(to the engine 1)

2.Install:
● Rubber boot 2
NOTE:
Be sure to position the rubber boot so that
the tang 3 faces towards the left.
8 - 46

– +
ELEC
9
– +
ELEC
CHAPTER 9.
ELECTRICAL
ELECTRICAL COMPONENTS .......................................................................9-1
SWITCH INSPECTION ..................................................................................9-2

SWITCH INSPECTION ..........................................................................9-2
INSPECTING A SWITCH SHOWN IN THE MANUAL .........................9-2
SWITCH CONTINUITY INSPECTION ...................................................9-3
IGNITION SYSTEM .......................................................................................9-5

CIRCUIT DIAGRAM ...............................................................................9-5
TROUBLESHOOTING ...........................................................................9-6
ELECTRIC STARTING SYSTEM .................................................................9-11

CIRCUIT DIAGRAM .............................................................................9-11
STARTING CIRCUIT OPERATION ......................................................9-12
TROUBLESHOOTING .........................................................................9-13
STARTER MOTOR ..............................................................................9-17
STARTER MOTOR INSPECTION .......................................................9-18
STARTER MOTOR ASSEMBLY .........................................................9-19
CHARGING SYSTEM ..................................................................................9-20

CIRCUIT DIAGRAM .............................................................................9-20
LIGHTING SYSTEM ....................................................................................9-23

CIRCUIT DIAGRAM .............................................................................9-23
LIGHTING SYSTEM CHECK ...............................................................9-26
SIGNAL SYSTEM ........................................................................................9-29

CIRCUIT DIAGRAM .............................................................................9-29
SIGNAL SYSTEM CHECK ...................................................................9-32
COOLING SYSTEM .....................................................................................9-40

CIRCUIT DIAGRAM .............................................................................9-40
TROUBLESHOOTING ........................................................................9-41
2WD/4WD SELECTING SYSTEM ..............................................................9-45

CIRCUIT DIAGRAM .............................................................................9-45

– +
ELEC

– +
ELECTRICAL COMPONENTS ELEC
EB800000
ELECTRICAL
ELECTRICAL COMPONENTS
1 Indicator light 9 Main fuse G Park switch O Fan
2 Main switch 0 Starter relay H Speed sensor P Headlight
3 On command four- A CDI unit I Reverse switch Q Circuit breaker (fan)
wheel drive switch B Starting circuit J Thermo switch R Auxiliary DC jack
4 Diode cut-off relay K Gear motor S Horn switch
5 Rear brake switch C Reverse relay L Four-wheel drive (For GB, F, CH, Oceania)
6 Handlebar switch (left) D Fuse box switch T Horn
7 Battery E Rectifier/regulator M Ignition coil (For GB, F, CH, Oceania)
8 Taillight F Neutral switch N Thermo switch
9-1

– +
SWITCH INSPECTION ELEC
SWITCH INSPECTION
SWITCH INSPECTION
Use a pocket tester to check the terminals
for continuity. If the continuity is faulty at
any point, replace the switch.
Pocket tester:
P/N. YU-03112, 90890-03112
NOTE:
● Set the pocket tester to “0” before starting
the test.
● The pocket tester should be set to the “Ω ×
1” range when testing the switch for con-

tinuity.
● Turn the switch on and off a few times
when checking it.
INSPECTING A SWITCH SHOWN IN THE

MANUAL
The terminal connections for switches
(main switch, handlebar switch, engine
stop switch, light switch, etc.) are shown in
a chart similar to the one on the left.
This chart shows the switch positions in the
column and the switch lead colors in the
top row.
For each switch position, “ ” indi-
cates the terminals with continuity.
The example chart shows that:
1 There is continuity between the “Black
and Black/White” leads when the switch
is set to “OFF”.
2 There is continuity between the “Red and
Brown” leads when the switch is set to
“ON”.
9-2

– +
SWITCH CONTINUITY INSPECTION
Refer to “SWITCH INSPECTION” and check for continuity between lead terminals.
Poor connection, no continuity → Correct or replace.
The coupler locations are circled.
*
9-3

– +
1 Lights switch
2 Engine stop switch
3 Starter switch
4 Main switch
5 On command four-wheel drive switch
6 Rear brake switch
7 Four-wheel drive switch
8 Reverse switch
9 Park switch
0 Neutral switch
A Fuse
B Horn switch (For GB, F, CH, Oceania)
9-4

A B C
G/W G/L Br/W W W Br/W

O O
EB802000
W/G W/L G/W L/Y Y/B G/Y Sb

Sb Sb Sb L/B L/B Sb
B B W/R R W B R/W B/W O
L/R L/R R/B B B R/B
(BLACK) (BLACK) (BLACK) (BLACK)
(BLUE) (BLUE)
WIRE HARNESS SUB-WIRE HARNESS 2 WIRE HARNESS IGNITION COIL LEAD WIRE HARNESS SUB-WIRE HARNESS 1
R R O B O
W/L W/L
D
W/R W/R
W/G W/G B B
W/G R R W/G Y/B C E
W/R W/L W/L W/R R/W
B/W
W W G/W L/Y L/Y
1 W W R Sb W W
CIRCUIT DIAGRAM
W W 2 F
W W B
W W W W
L/R
P O/R L/Y W
R R R G/Y G/Y B
B/W B
A B
IGNITION SYSTEM
B R R G/Y
4 R R R
W W W L/W L/B
5 L/R G/Y

(BLACK)
(BLACK) A
B L/W B
L/R
6 L/W
Y/B B B Br/L
B L/B
B
0 (BLACK)
B
Y/B L/W 8
R/W R/W B
G/Y B B
B 7 (BLACK)
R B R/W G
R/W
B
3
ON B B/W B/W B
OFF R Br Br/L R
R/B
R/W
Br/L B/W C
B
R/B
9
H
9-5
R/B L
Br/L
(DARK GRAY)
Br/L Br/L Br/L
Z X T R/W R/W R/W

L/B L B B L
I
W/L L/B
Sb R/W
JKL
R/Y P Br/R B
Br/R W P G/L R/W
R/W W/L L/R R/W C
B/W Br/R R/W
R/Y L/B Br/R (BLACK) B
Br L/R Br/W Br/R QR W/L Sb G/L L/R

[ U W Br/R R/W Sb
\ ] B/W ` L/G B B Sb R/W G/L
2WD W/L R/W
L/B L/B G/L R/W
OFF OFF OFF 4WD R/W L/R
L/B R/Y Br R/W
LO ON PUSH (BROWN) (BROWN) (BLACK)
G Y Y G
HI
B L L B W W/L 1 CDI magneto
IGNITION SYSTEM
Br/W B
G/W B
Sb L/B M R/W G/L 3 Main switch
L Y G B P
W/L (RED)
B G/W 4 Battery
C C
Y C C 5 Main fuse
G W/B
L S
L Y G Y G
9 Ignition fuse
Sb G/W
B P B Sb W
ELEC
A A
c b a a Br/W L/B C CDI unit
L Sb G/L
B L L B D Ignition coil
–
Y G Y G
(GRAY) (GRAY) B V W
B B
E Spark plug
B B B O N
G Y G Y ] Engine stop switch
B
+
B B L/B Br/W Sb
– +
IGNITION SYSTEM ELEC
EB802010
TROUBLESHOOTING
IF THE IGNITION SYSTEM FAILS TO OPERATE (NO SPARK OR INTERMITTENT SPARK):
Procedure
Check:
1.Fuse (main, ignition) 7.Engine stop switch
2.Battery 8.Main switch
3.Spark plugs 9.Pickup coil resistance
4.Ignition spark gap 10.Charging/rotor rotation direction detec-
5.Spark plug cap resistance tion coil resistance
6.Ignition coil resistance 11.Wiring connection
(the entire ignition system)
NOTE:
● Remove the following part(s) before trou-
Dynamic spark tester:
P/N. YM-34487
bleshooting: Ignition checker:
1)Seat P/N. 90890-06754
2)Fuel tank side panels Pocket tester:
3)Front carrier P/N. YU-03112, 90890-03112
4)Front fender
● Use the following special tool(s) for trou-
bleshooting.
EB802011
NO CONTINUITY
1.Fuse (main, ignition)
Refer to “SWITCH INSPECTION”.
CONTINUITY Replace the fuse.

EB802012
2.Battery
INCORRECT
● Check the battery condition.
Refer to “BATTERY INSPECTION” in
CHAPTER 3.
Open-circuit voltage: ● Clean the battery terminals.
12.8 V or more at 20 ˚C (68 ˚F) ● Recharge or replace the battery.
CORRECT
3.Spark plug Standard spark plug:

D8EA/NGK, X24ES-U/DENSO
● Check the spark plug condition.
● Check the spark plug type.
● Check the spark plug gap.
Refer to “SPARK PLUG INSPECTION” in
CHAPTER 3.
9-6

– +
INCORRECT
Spark plug gap:
0.6 ~ 0.7 mm (0.02 ~ 0.03 in)
CORRECT
Repair or replace the spark plug.
For CDN
4.Ignition spark gap
● Disconnect the spark plug cap from the
spark plug.
● Connect the dynamic spark tester 1 as
shown.
2 Spark plug cap
3 Spark plug
● Turn the main switch to “ON”.
● Check the ignition spark gap.
● Crank the engine by pushing the starter MEETS SPECIFICATION
switch, and increase the spark gap until
a misfiring occurs.
Minimum spark gap:
6.0 mm (0.24 in) The ignition system is not faulty.
OUT OF
SPECIFICATION
OR NO SPARK
For GB, F, CH, Oceania
4.Ignition spark gap
● Disconnect the spark plug cap from
spark plug.
● Connect the ignition checker 1 as
shown.
2 Spark plug cap
● Check the ignition spark gap a.
● Crank the engine by pushing the starter
switch, and increase the spark gap until MEETS SPECIFICATION
a misfire occurs.
Minimum spark gap:
6.0 mm (0.24 in)
The ignition system is not faulty.
OUT OF
SPECIFICATION
OR NO SPARK
*
9-7

– +
5.Spark plug cap resistance

● Remove the spark plug cap.
● Connect the pocket tester (Ω × 1k) to the
spark plug cap.
OUT OF SPECIFICATION
● Check that the spark plug cap has the
specified resistance.
Spark plug cap resistance:

10 kΩ at 20 ˚C (68 ˚F) Replace the spark plug cap.
MEETS
SPECIFICATION
6.Ignition coil resistance Tester (+) lead → Orange lead terminal

Tester (–) lead → Ignition coil base
● Disconnect the ignition coil connector
from the wire harness.
● Connect the pocket tester (Ω × 1) to the
ignition coil.
● Check that the primary coil has the spec-

ified resistance.
Tester (+) lead → Orange lead terminal
Primary coil resistance: Tester (–) lead → Spark plug lead
0.18 ~ 0.28 Ω at 20 ˚C (68 ˚F)
● Connect the pocket tester (Ω × 1k) to the

ignition coil.
9-8

– +
● Check that the secondary coil has the OUT OF SPECIFICATION

specified resistance.
Secondary coil resistance:

6.32 ~ 9.48 kΩ at 20 ˚C (68 ˚F) Replace the ignition coil.
BOTH MEET
SPECIFICATION
INCORRECT
7.Engine stop switch
CORRECT Replace the handlebar switch (left).
INCORRECT
8.Main switch
CORRECT Replace the main switch.
9.Pickup coil resistance

● Disconnect the CDI magneto coupler
● Connect the pocket tester (Ω × 100) to
the pickup coil terminal.
Tester (+) lead → White/Red terminal 1
Tester (–) lead → White/Green terminal 2
● Check the pickup coil for the specified OUT OF SPECIFICATION

resistance.
Pickup coil resistance:

459 ~ 561 Ω at 20 ˚C (68 ˚F)
(White/Red – White/Green) Replace the pickup coil/starter assembly.
MEETS
SPECIFICATION
9-9

– +
*
C0NTINUITY
10.Charging/rotor rotation direction detec-

tion coil resistance
the charging/rotor rotation direction
detection coil terminal.
Tester (+) lead → Red terminal 1
Tester (–) lead → White/Blue terminal 2
● Check the charging/rotor rotation direction

detection coil for the specified resistance. OUT OF SPECIFICATION
Rotor ratation direction sensing
coil resistance:
0.104 ~ 0.127 Ω at 20 ˚C (68 ˚F)
(Red – White/Blue) Replace the pickup coil/starter assembly.
MEETS
SPECIFICATION
11.Wiring connection
● Check the connections of the entire igni- POOR CONNECTION
tion system.
Refer to “CIRCUIT DIAGRAM”.
CORRECT Properly connect the ignition system.
Replace the CDI unit.
9 - 10

A B C

O O W/G W/L G/W L/Y Y/B G/Y Sb
Sb Sb Sb L/B L/B Sb
EB803000

L/R L/R R/B B B R/B
(BLUE) (BLUE)
R R O B O
W/L W/L
D
W/R W/R
W/G W/G B B
W/G R R W/G Y/B C E
W/R W/L W/L W/R R/W
B/W
W W G/W L/Y L/Y
W W
1 W W 2 R Sb W W F
CIRCUIT DIAGRAM
W W B
W W W W
L/R
P O/R L/Y W
R R R G/Y G/Y B
B/W B
A B
B R R G/Y
4 R R R
W W W L/W L/B
5 L/R G/Y
(BLACK)

(BLACK) A
B L/W B
L/R
6 L/W
Y/B B B Br/L
B L/B
B
0 (BLACK)
B
Y/B L/W 8
R/W R/W B
G/Y B B
B 7 (BLACK)
R B R/W G
R/W
B
3
ON B B/W B/W B
ELECTRIC STARTING SYSTEM
OFF R Br Br/L R
R/B
R/W
Br/L B/W C
B
R/B
9
H
R/B L
9 - 11
Br/L
(DARK GRAY)
Br/L Br/L Br/L
Z X T R/W R/W R/W

L/B L B B L
I
W/L L/B
JKL 3 Main switch

Sb R/W
R/Y P Br/R B
Br/R W P G/L R/W 4 Battery
R/W W/L L/R R/W C
B/W Br/R R/W
R/Y L/B Br/R (BLACK) 5 Main fuse B

[ U W Br/R R/W Sb 6 Starter relay
2WD W/L R/W
L/B L/B G/L R/W
L/B R/Y Br R/W 7 Starter motor
G Y Y G
HI
B L L B W W/L 8 Starting circuit cut-off relay
Br/W B
ELECTRIC STARTING SYSTEM
G/W B
Sb L/B M R/W G/L 9 Ignition fuse
L Y G B P
W/L (RED)
B G/W 0 Park switch
C C
Y C C A Diode 1
G W/B
L S
L Y G Y G B Rear brake switch
Sb G/W
B P B Sb W
A A
Br/W L/B
ELEC
c b a a C CDI unit
L Sb G/L
B L L B O Neutral switch
Y G Y G
–
(GRAY) (GRAY) B W
B B
V
] Engine stop switch
B B B O N
G Y G Y _ Starter switch
B
L/B Br/W Sb
+
B B
– +
ELECTRIC STARTING SYSTEM ELEC
STARTING CIRCUIT OPERATION
The starting circuit on this model consists
of the starter motor, starter relay, starting
circuit cut-off relay, rear brake switch, park
switch CDI unit and neutral switch. If the
main switch is on and the engine stop
switch is in the RUN position, the starter
motor can be operated only if:
● The transmission is in neutral (the neu-

tral switch is closed).
or
● The transmission is in park (the park
switch is closed).
● You pull in the rear brake lever (the rear
brake switch is closed).
The starting circuit cut-off relay prevents

the starter from operating when the select
lever is in gear or in reverse and the rear
brake lever is free. In this instance, the start-
ing circuit cut-off relay is off so that current
cannot reach the starter motor.
1 Main fuse
2 Battery
3 Starter relay
4 Starter motor
5 Starting circuit cut-off relay
6 Start switch
7 Ignition fuse
8 CDI unit
9 Engine stop switch
0 Rear brake switch
A Diode
B Park switch
C Neutral switch
Å TO MAIN SWITCH
ı FROM MAIN SWITCH
9 - 12

– +
EB803020
TROUBLESHOOTING
IF THE STARTER MOTOR FAILS TO OPERATE:
Procedure
Check:
1.Fuse (main, ignition) 8.Neutral switch
2.Battery 9.Rear brake switch
3.Starter motor 10.Park switch
4.Starting circuit cut-off relay 11.Start switch
5.Starter relay 12.Diode
6.Main switch 13.Wiring connection
7.Engine stop switch (the entire starting system)
NOTE:
● Remove the following part(s) before trou- Pocket tester:
bleshooting: P/N. YU-03112, 90890-03112
1)Seat
2)Fuel tank side panels
3)Fuel tank
4)Air cleaner case
5)Front carrier
6)Front fender panel
bleshooting.
EB802011
NO CONTINUITY
1.Fuse (main, ignition)

EB802012
2.Battery
INCORRECT
CHAPTER 3.
● Clean the battery terminals.
Open-circuit voltage:
CORRECT
9 - 13

– +
*
C0NTINUITY
*
3.Starter motor WARNING
● A wire that is used as a jumper lead must
● Connect the battery positive terminal 1
have the equivalent capacity or more as
and starter motor cable 2 using a
that of the battery lead, otherwise the
jumper lead 3 .
●
*
Check the operation of the starter motor.
jumper lead may burn.
● This check is likely to produce sparks, so
be sure that no flammable gas or fluid is
in the vicinity.
DOES NOT TURN
Repair or replace the starter motor.
TURNS
4.Starting circuit cut-off relay

● Remove the starting circuit cut-off relay
● Connect the pocket tester (Ω × 1) and the
battery (12 V) to the starting circuit cut-
off relay terminals.
Battery (+) terminal →
Red/White terminal 1
Battery (–) terminal →
Yellow/Black terminal 2
Tester (+) lead → Red/White terminal 3
Tester (–) lead → Blue/White terminal 4
NO CONTINUITY
● Check the starting circuit cut-off relay for
continuity.
CONTINUITY
Replace the starting circuit cut-off relay.
9 - 14

– +
*
C0NTINUITY
5.Starter relay
● Remove the starter relay from the wire
harness.
● Connect the pocket tester (Ω × 1) and the
battery (12 V) to the starter relay termi-
nals.

Blue/White terminal 1
NO CONTINUITY
Blue/Black terminal 2
Tester (+) lead → Red terminal 3
Tester (–) lead → Black terminal 4
● Check the starter relay for continuity. Replace the starter relay.
CONTINUITY
INCORRECT
6.Main switch
INCORRECT
7.Engine stop switch
CORRECT Replace the handlebar switch (right).
8.Neutral switch INCORRECT
CORRECT Replace the neutral switch.
INCORRECT
9.Rear brake switch
CORRECT Replace the rear brake switch.
* 9 - 15

– +
*
C0NTINUITY
INCORRECT
10.Park switch
CORRECT Replace the park switch.
INCORRECT
11.Start switch
12.Diode
● Remove the diode from the coupler.
diode terminals as shown.
● Check the diode for continuity as fol-
lows.
Tester positive probe →
Blue/Red 1 Continu-
Tester negative probe → ity NOTE:
Green/Yellow 2 When you switch the tester’s positive and
negative probes, the readings in the left
Tester positive probe → chart will be reversed.
Green/Yellow 2 No conti-
Tester negative probe → nuity INCORRECT
Blue/Red 1
CORRECT
Replace the diode.
EB803028
POOR CONNECTION
13.Wiring connection
● Check the connections of the entire start-
ing system.
Refer to “CIRCUIT DIAGRAM”. Properly connect the starting system.
9 - 16

– +
STARTER MOTOR

Starter motor removal Remove the parts in the order below.
1 Starter motor lead 1
2 Starter motor/O-ring 1/1 For installation, reverse the removal
procedure.
Starter motor disassembly Disassemble the parts in the order
below.
1 Bracket 1 1
2 Washer kit
3 Bracket 2 1
Refer to “STARTER MOTOR ASSEM-
4 Shims
BLY”.
5 Brush seat 1/brush seat 2 1/2
6 Armature coil 1
7 Yoke 1
procedure.
9 - 17

– +
STARTER MOTOR INSPECTION
1.Inspect:
● Commutator
Dirty → Clean it with #600 grit sandpaper.

2.Measure:
● Commutator diameter a
Out of specification → Replace the starter

motor.
Outside diameter:
28 mm (1.10 in)
<Wear limit>:
27 mm (1.06 in)
3.Measure:
● Mica undercut b
Out of specification → Scrape the mica
using a hacksaw blade.
Mica undercut:
0.7 mm (0.03 in)
NOTE:
Scrape the mica to the proper measure-
ment using a hacksaw blade which has
been grounded to fit the commutator.
4.Inspect:
● Armature coil (insulation/continuity)
Defects → Replace the starter motor.

*********************************
Armature coil inspection steps:
● Connect the pocket tester for the continu-
ity check 1 and insulation check 2.
● Measure the armature resistances.
Armature coil resistance:

Continuity check 1:
0.025 ~ 0.035 Ω at 20 ˚C (68 ˚F)
Insulation check 2:
More than 1 MΩ at 20 ˚C (68 ˚F)
● If the resistance is incorrect, replace the

starter motor.
*********************************
9 - 18

– +
5.Measure:
● Brush length a (each)
Out of specification → Replace the brush.
Brush length:
12.5 mm (0.49 in)
<Wear limit>:
5 mm (0.20 in)
6.Measure:
● Brush spring force
Fatigue/out of specification → Replace as

a set.
Brush spring force:

7.65 ~ 10.01 Nm
(780 ~ 1,020 g, 27.5 ~ 36.0 oz)
7.Inspect:
● Oil seal
● Bushing
● Bearing
● O-rings
STARTER MOTOR ASSEMBLY

1.Install:
● Yoke
● Brackets
NOTE:
Align the match marks a on the yoke with
the match marks b on the brackets.
9 - 19

– +
CHARGING SYSTEM ELEC
EB804000
CHARGING SYSTEM
CIRCUIT DIAGRAM
A B C
G/W G/L Br/W W

O O
Sb Sb Sb L/B
B B
L/R L/R R/B B
(BLACK) (BLACK)
(BLUE)
WIRE HARNESS SUB-WIRE HARNESS 2 WIRE HARNESS IGNITION COIL LEAD WIRE HARNESS S
R
W/L
W/R
W/G
W/G R R W/G
W/R W/L W/L W/R
W W
W W
1 W W 2 R
W W B
W W W W
R R R
B
W W
R
W
4 R R R
5 L/W L/B
(BLACK)
(BLACK)
B L/W
6 L/W
L/B Y/B
B B
B
Y/B L/W 8
R/W R/W
R B
B 7 R/W
R/W
3
ON B B/W B/W B
OFF R Br Br/L R
R/W
Br/L B/W
B
Br/L
Br/L Br/L Br/L
Z X T
R/Y P Br/R
Br
R/
B/W Br/R R/W
R/Y L/B Br/R
[ U Br L/R Br/W Br/R QR

\ ] B/W ` 2WD L/G B B Sb
W
W
OFF OFF OFF 4WD L/B L/B
L/B R/Y Br R/W
LO ON PUSH (BROWN) (BROWN)
G Y Y G
HI
B L L B W W/L
Br/W B
Sb L/B
L Y G B P
W/L
C C
Y G W/B
C C
L
L S
Y G Y G
B P B Sb W
c b a a Br/W L/B 1 CDI magneto
L
2 Rectifier/regulator
L B
4 Battery
(GRAY) B
Y G Y G
V W
B B
5 Main fuse
9 - 20

– +
EB804010
TROUBLESHOOTING
IF THE BATTERY IS NOT CHARGED:
Procedure
Check:
1.Fuse (main) 4.Charging coil resistance
2.Battery 5.Wiring connections
3.Charging voltage (the entire charging system)
NOTE:
● Remove the following part(s) before trou- Inductive tachometer:
bleshooting: P/N. YU-8036-A
Engine tachometer:
1)Seat
P/N. 90890-03113
2)Fuel tank side panels Pocket tester:
● Use the following special tool(s) for trou- P/N. YU-03112, 90890-03112
bleshooting.
EB802011
NO CONTINUITY
1.Fuse (main)

EB802012
2.Battery
INCORRECT
CHAPTER 3.
CORRECT
EB804011
3.Charging voltage
● Connect the engine tachometer to the
spark plug lead #1.
● Connect the pocket tester (DC 20V) to
the battery.
Tester (+) lead → Battery (+) terminal
Tester (–) lead → Battery (–) terminal
9 - 21

– +
● Start the engine and accelerate to about
3,000 r/min.
Charging voltage: MEETS SPECIFICATION
14 V at 1,000 r/min
NOTE:
Use a fully charged battery. The charging circuit is not faulty.
OUT OF
SPECIFICATION
EB804012
4.Charging coil resistance

charging coils.
Tester (+) lead → White terminal 1
Tester (–) lead → White terminal 2
Tester (+) lead → White terminal 1
Tester (–) lead → White terminal 3 OUT OF SPECIFICATION
● Measure the stator coil resistance.

Charging coil resistance:
0.70 ~ 0.86 Ω at 20 ˚C (68 ˚F) Replace the pickup coil/stator assembly.
MEETS
SPECIFICATION
EB804015
5.Wiring connections
POOR CONNECTION
● Check the connections of the entire
charging system.
CORRECT Properly connect the charging system.
Replace the rectifier/regulator.
9 - 22

– +
LIGHTING SYSTEM ELEC
EB805000
LIGHTING SYSTEM
CIRCUIT DIAGRAM
L/R L/R
(BLACK) (BLACK)
WIRE HARNESS SUB-WIRE HARNESS 2 WIRE HARNESS IGNITION COIL LEAD WI
R
W/L
W/R
W/G
W/G R R W/G
W/R W/L W/L W/R
W W
W W
1 W W 2 R
W W B
W W W W
R R R
B
W W
R
W
4 R R R
5 L/W L/B
(BLACK)
(BLACK)
B L/W
6 L/W
B L/B
B
Y/B L/W
B
R/W R/W
R B
B 7
R/
3
ON B B/W B/W B
OFF R Br Br/L R
R/
Br/L B/W
B
Br
Br/L Br/L Br/L
Z X T
R/Y P Br/R
B/W
R/Y L/B Br/R
[ U Br L/R Br/W Br/R Q

\ ] B/W ` 2WD L/G B B Sb
OFF OFF OFF 4WD L/B L/B
L/B R/Y Br R/W
LO ON PUSH (BROWN) (BROWN)
G Y Y G
HI
B L L B
Br/W B
Sb L/B
L Y G B P
C C
Y G W/B
C C
L
L Y G Y G
B P B Sb W
c b a a Br/W L/B 3 Main switch
L
4 Battery
B L L B
5 Main fuse
(GRAY) (GRAY) B
Y G
B
Y G
B
V ZW Headlight fuse
B B B \ Lights switch
G Y G Y
B
B B Headlight
L/B Br/W aSb
b Taillight
c Speedometer light
9 - 23

– +
EB805010
TROUBLESHOOTING
IF THE HEADLIGHT, TAILLIGHT AND/OR METER LIGHT FAIL TO COME ON:
Procedure
Check:
1.Fuse (main) 4.Lights switch
3.Main switch (the entire lighting system)
NOTE:
1)Seat
2)Front carrier
bleshooting.
EB802011
NO CONTINUITY
1.Fuse (main, headlight)

EB802012
2.Battery
INCORRECT
CHAPTER 3.
CORRECT
9 - 24

– +
*
C0NTINUITY
INCORRECT
3.Main switch
INCORRECT
4.Lights switch
CORRECT Lights switch is faulty, replace the handle-

bar switch (left).
EB805013
5.Wiring connection
POOR CONNECTION
● Check the connections of the entire light-
ing system.
Refer to “WIRING DIAGRAM”.
CORRECT Properly connect the lighting system.
Check the condition of each of the lighting

system’s circuits.
Refer to “LIGHTING SYSTEM CHECK”.
9 - 25

– +
EB805020
LIGHTING SYSTEM CHECK
1.If the headlights fail to come on:
NO CONTINUITY
1.Bulb and bulb socket
● Check the bulb and bulb socket for conti-
nuity.
Replace the bulb and/or bulb socket.
CONTINUITY
2.Voltage
● Connect the pocket tester (DC 20 V) to
the headlight couplers.
Å ı
Tester (+) lead →

Green terminal 1 or Yellow terminal 2
Å When the lights switch is on “LO”.
ı When the lights switch is on “HI”.
● Turn the lights switch to “LO” or “HI”.
● Check the voltage (12 V) of the “Green”
and “Yellow” leads on the bulb socket
The wiring circuit from the main switch to
connector.
the bulb socket connector is faulty, repair
MEETS it.
SPECIFICATION
This circuit is not faulty.
9 - 26

– +
EB805021
2.If the tailight fails to come on:
NO CONTINUITY
nuity.
CONTINUITY
2.Voltage
● Connect the pocket tester (20 V) to the
bulb socket coupler.
Tester (+) lead → Blue lead 1
Tester (–) lead → Black lead 2
● Check the voltage (12 V) of the “Blue”
lead on the bulb socket connector.
MEETS the bulb socket connector is faulty, repair
SPECIFICATION it.
9 - 27

– +
3.If the speedometer light (option) fails to
come on:
1.Bulb and bulb socket NO CONTINUITY

nuity.
CONTINUITY
2.Voltage
● Connect the pocket tester (20 V) to the
bulb socket coupler.
Tester (+) lead → Blue terminal 1
● Check the voltage (12 V) of the “Blue”
lead on the bulb socket connector.
MEETS the bulb socket connector is faulty, repair
SPECIFICATION it.
9 - 28

3 Main switch
EB806000
4 Battery
5 Main fuse
9 Ignition fuse
G/W G/L Br/W W W Br/W 0 Park switch
Sb Sb Sb L/B L/B Sb
L/R L/R R/B B B R/B
(BLUE) (BLUE)
J Neutral indicator light
R R O B O
K Reverse indicator light
D
CIRCUIT DIAGRAM
W/L W/L
W/R W/R L Park indicator light
W/G W/G B B
W/G R R W/G Y/B C E
SIGNAL SYSTEM
W/R W/L W/L W/R R/W M Reverse relay

B/W
W W G/W L/Y L/Y
W W
1 W W 2 R Sb W W
N Reverse
F switch
W W B
W W W W
L/R

P O/R L/Y W
R R G/Y G/Y B
O Neutral switch
R B/W B
A B
B R R R R G/Y P Diode 2
4 R
W W W L/W L/B
5 L/R G/Y
(BLACK)
(BLACK)
B
A
Q Four-wheel drive indicator
L/W B
L/R
6 L/W
Y/B B B light
Br/L
B L/B
B
0 (BLACK)
B
Y/B L/W 8 R Coolant tempera-
R/W R/W B
G/Y B B
B 7 (BLACK)
R B R/W ture indicator light
G
R/W
B
3 S Thermo switch
ON B B/W B/W B
OFF R Br Br/L R
R/B
T Four-wheel drive fuse
R/W
Br/L B/W C
B
W Four-wheel drive switch
R/B
9 _HStart switch
9 - 29
R/B L
Br/L d Signal fuse
(DARK GRAY)
A
e Horn switch
L
Br/L Br/L Br/L Br/L f Horn

d Z X T R/W R/W R/W
L/B L B B L
I
W/L L/B
Sb R/W
JKL Å For GB, F, CH, Oceania
Br R/Y P Br/R B
Br/R W P G/L R/W
R/W W/L L/R R/W C
B/W Br/R R/W
Br Br (BLACK) B
R/Y L/B Br/R
g B B
[ U W Br/R R/W Sb
2WD W/L R/W
L/B L/B G/L R/W
L/B R/Y Br R/W
G Y Y G
HI
B L L B W W/L
Br/W B
G/W B
Sb L/B M R/W G/L
L Y G B P
Br W/L (RED)
SIGNAL SYSTEM
B G/W
C C
Y C C
Br Br G W/B
OFF L
ON B B S
L Y G Y G Sb G/W
B P B Sb W
P B A A
c b a a Br/W L/B
e L Sb G/L
B L L B
B Y G Y G
(GRAY) (GRAY) B V W
P B B B
ELEC
f B B B O N
G Y G Y
B
B B L/B Br/W Sb
–
+
– +
SIGNAL SYSTEM ELEC
EB806010
TROUBLESHOOTING
IF THE INDICATOR LIGHT FAILS TO COME ON:
Procedure
Check:
1.Fuse (main, ignition, signal, four-wheel drive)
2.Battery
3.Main switch
(the entire signal system)
NOTE:
1)Seat
2)Fuel tank
3)Air cleaner case
4)Front carrier
bleshooting.
EB802011
NO CONTINUITY
1.Fuse (main, ignition, signal, four-wheel
drive)
Replace the fuse.
CONTINUITY
EB802012
2.Battery
INCORRECT
CHAPTER 3.
CORRECT
9 - 30

– +
SIGNAL SYSTEM ELEC
*
C0NTINUITY
INCORRECT
3.Main switch
EB806011
POOR CONNECTION
● Check the connections of the entire sig-
nal system.
Refer to “CIRCUIT DIAGRAM”. Properly connect the signal system.
CORRECT
Check the condition of each of the signal

system’s circuits.
Refer to “SIGNAL SYSTEM”.
9 - 31

– +
SIGNAL SYSTEM ELEC
SIGNAL SYSTEM CHECK
1.Horn does not sound.
INCORRECT
1.“HORN” switch.
CORRECT Replace the horn switch.
2.Voltage
the horn lead.
Tester (+) lead → Pink lead 1
Tester (–) lead → Frame ground
● Push the “HORN” switch.
● Check for voltage (12 V) on the “Pink”
lead at the horn terminal.
Wiring circuit from main switch to horn
MEETS terminal is faulty, repair.
SPECIFICATION
3.Horn
● Disconnect the “Black” lead at the horn
terminal.
● Connect a jumper lead 1 to the horn ter-
minal and ground the jumper lead.
HORN IS SOUNDED
The horn is not faulty.
HORN IS NOT
SOUNDED
9 - 32

– +
SIGNAL SYSTEM ELEC
4.Voltage
the horn at the “Black” terminal.
Tester (+) lead → Black lead 1
● Check for voltage (12 V) on the “Black”
lead at the horn terminal.
Replace the horn.
MEETS
SPECIFICATION
Adjust or replace the horn.
9 - 33

– +
SIGNAL SYSTEM ELEC
EB806024
2.If the neutral indicator light fails to come
on:
NO CONTINUITY
nuity.
CONTINUITY
NO CONTINUITY
2.Neutral switch
CONTINUITY Replace the neutral switch.
3.Voltage
the bulb socket coupler.
Tester (–) lead → Sky blue terminal 2
● Check the voltage (12 V).
MEETS
SPECIFICATION The wiring circuit from the main switch to
This circuit is not faulty. it.
9 - 34

– +
SIGNAL SYSTEM ELEC
3.If the reverse indicator light fails to come
on:
NO CONTINUITY
nuity.
CONTINUITY
NO CONTINUITY
2.Reverse switch
CONTINUITY Replace the reverse switch.
3.Reverse relay
● Remove the reverse relay from the wire
harness.
● Connect the pocket tester (Ω × 1) and
battery (12 V) to the reverse relay termi-
nals.

Red/White terminal 1
NO CONTINUITY
Green/White terminal 2
Tester (+) lead → Green/Blue terminal 3
● Check the reverse relay for continuity. Replace the reverse relay.
CONTINUITY
4.Voltage
Tester (–) lead → Green/Blue terminal 2
9 - 35

– +
SIGNAL SYSTEM ELEC
MEETS
4.If the park indicator light fails to come on:

NO CONTINUITY
nuity.
CONTINUITY Replace the bulb and/or bulb socket.
NO CONTINUITY
2.Park switch
CONTINUITY Replace the park switch.
3.Voltage
Tester (–) lead → Blue/Red terminal 2
MEETS
9 - 36

– +
SIGNAL SYSTEM ELEC
5.If the coolant temperature indicator light does not come on when the start switch is pushed
on, or if the coolant temperature indicator light does not come on when the temperature is
high (more than 107 ~ 113 ˚C (224.6 ~ 235.4 ˚F)):
NO CONTINUITY
nuity.
CONTINUITY
2.Thermo switch
● Remove the thermo switch from the
cylinder head.
thermo switch 1.
● Immerse the thermo switch in coolant
2.
● Check the thermo switch for continuity.
While heating the coolant use a ther-
mometer 3 to record the temperatures.
Test Water temperature Good
step Thermo switch condition
0 ~ 103 ˚C
1
(32 ~ 217.4 ˚F)
×
More than
2 110 ± 3 ˚C
(230 ± 5.4 ˚F)
110 ~ 103 ˚C
3*
(230 ~ 217.4 ˚F)
Less than 103 ˚C
4*
(217.4 ˚F)
×
Tests 1 & 2; Heat-up tests
Tests 3* & 4*; Cool-down tests
: Continuity × : No continuity
WARNING
Handle the thermo switch with special
care.
Never subject it to a strong shock or
allow it to be dropped. Should it be
dropped, it must be replaced. BAD CONDITION
Thermo switch:
8 Nm (0.8 m • kg, 5.8 ft • lb)
T.
Three bond sealock® #10

R.
Replace the thermo switch.
GOOD
CONDITION
*
9 - 37

– +
SIGNAL SYSTEM ELEC
*
C0NTINUITY
3.Voltage
the bulb socket connector.
Tester (+) lead → Red/White lead 1
MEETS
it.
4.Diode
• Remove the diode from the coupler.
• Connect the pocket tester (Ω × 1) to the
diode terminals as shown.
• Check the diode for continuity as fol-
lows.
Tester positive probe →
Blue/Black 1 Continu- NOTE:
Tester negative probe → ity When you switch the tester’s positive and
White/Blue 2 negative probes, the readings in the left
Tester positive probe → chart will be reversed.
White/Blue 2 No conti-
Tester negative probe → nuity
Blue/Black 1 INCORRECT
CORRECT
* Replace the diode.
9 - 38

– +
SIGNAL SYSTEM ELEC
*
C0NTINUITY
INCORRECT
5.Start switch
6.If the four-wheel drive indicator light fails to come on:
NO CONTINUITY
nuity. Replace the bulb and/or bulb socket.
CONTINUITY
NO CONTINUITY
2.Four-wheel drive switch
CONTINUITY Replace the four-wheel drive switch.
3.Voltage
the bulb socket lead.
Tester (+) lead → Brown/Red terminal 1
MEETS
9 - 39

A B C

3 Main switch
Sb Sb Sb L/B L/B Sb
L/R L/R R/B B B R/B 4 Battery
(BLUE) (BLUE)
5 Main fuse
R R O B O G Circuit
W/L W/L
D breaker (fan motor)
W/R W/R H Thermo switch
W/G W/G B B
W/G R R W/G Y/B C E
W/R W/L W/L W/R R/W I Fan motor
B/W
W W G/W L/Y L/Y
W W
1 W W 2 R Sb W W F
CIRCUIT DIAGRAM
W W B
W W W W
L/R
P O/R L/Y W
R R R G/Y G/Y B
B/W B
A B
B R R G/Y
R R R
COOLING SYSTEM
W W W
4
L/W L/B
5 L/R G/Y
(BLACK)

(BLACK) A
B L/W B
L/R
6 L/W
Y/B B B Br/L
B L/B
B
0 (BLACK)
B
Y/B L/W 8
R/W R/W B
G/Y B B
B 7 (BLACK)
R B R/W G
R/W
B
3
ON B B/W B/W B
OFF R Br Br/L R
R/B
R/W
Br/L B/W C
B
R/B
9
H
R/B L
9 - 40
Br/L
(DARK GRAY)
Br/L Br/L Br/L
Z X T R/W R/W R/W

L/B L B B L
I
W/L L/B
Sb R/W
JKL
R/Y P Br/R B
Br/R W P G/L R/W
R/W W/L L/R R/W C
B/W Br/R R/W
R/Y L/B Br/R (BLACK) B

[ U W Br/R R/W Sb
2WD W/L R/W
L/B L/B G/L R/W
L/B R/Y Br R/W
G Y Y G
HI
B L L B W W/L
Br/W B
COOLING SYSTEM
G/W B
Sb L/B M R/W G/L
L Y G B P
W/L (RED)
B G/W
C C
Y C C
G W/B
L S
L Y G Y G Sb G/W
B P B Sb W
A A
Br/W L/B
ELEC
c b a a
L Sb G/L
B L L B
Y G Y G
–
(GRAY) (GRAY) B W
B B
V
B B B O N
G Y G Y
B
L/B Br/W Sb
+
B B
– +
COOLING SYSTEM ELEC
TROUBLESHOOTING
IF THE FAN MOTOR DOES NOT MOVE:
Procedure
Check:
1.Fuse (main) 6.Thermo switch
2.Battery 7.Wiring connection
3.Main switch (the entire cooling system)
4.Fan motor
5.Circuit breaker (fan motor)
NOTE:
bleshooting. P/N. YU-03112, 90890-03112
1)Seat
2)Front carrier
3)Front fender
bleshooting.
EB802011
NO CONTINUITY
1.Fuse (main)

EB802012
2.Battery
INCORRECT
CHAPTER 3.
CORRECT
3.Main switch INCORRECT
9 - 41

– +
COOLING SYSTEM ELEC
*
C0NTINUITY
4.Fan motor
● Disconnect the fan motor coupler.
● Connect the battery (12 V) as shown.
Battery (+) lead → Blue terminal 1
Battery (–) lead → Black terminal 2
DOES NOT TURN
● Check the operation of the fan motor. Replace the fan motor.
TURNS
5.Circuit breaker (fan motor)

● Remove the circuit breaker from the wire
harness.
circuit breaker.
Circuit breaker resistance:

Zero Ω at 20 ˚C (68 ˚F) Replace the circuit breaker.
MEETS
SPECIFICATION
9 - 42

– +
COOLING SYSTEM ELEC
*
C0NTINUITY
6.Thermo switch
● Remove the thermo switch from the
radiator.
the thermo switch 1.
● Immerse the thermo switch in coolant
2.
● Check the thermo switch for continuity.
While heating the coolant use a ther-
mometer 3 to record the temperatures.
Test Water temperature Good
step Thermo switch condition
0 ~ 92 ± 3 ˚C
1
(32 ~ 197.6 ± 5.4 ˚F)
×
More than 98 ± 3 ˚C
2
(208.4 ± 5.4 ˚F)
98 to 92 ± 3 ˚C (208.4
3*
to 197.6 ± 5.4 ˚F)
Less than 29 ± 3 ˚C
4*
(197.6 ± 5.4 ˚F)
×
Tests 1 & 2; Heat-up tests
Tests 3* & 4*; Cool-down tests
: Continuity × : No continuity
WARNING
Handle the thermo switch with special
care.
Never subject it to a strong shock or
allow it to be dropped. Should it be
dropped, it must be replaced. BAD CONDITION
Thermo switch:
28 Nm (2.8 m • kg, 20 ft • lb)
T.
Three bond sealock® #10

R.
Replace the thermo switch.
GOOD
CONDITION
9 - 43

– +
COOLING SYSTEM ELEC
*
C0NTINUITY
EB803028
POOR CONNECTION
7.Wiring connection
● Check the connections of the entire start-
ing system.
Refer to “CIRCUIT DIAGRAM”. Properly connect the cooling system.
CORRECT
9 - 44

– +
2WD/4WD SELECTING SYSTEM ELEC
2WD/4WD SELECTING SYSTEM
CIRCUIT DIAGRAM
3 Main switch
4 Battery
5 Main fuse
T Four-wheel drive fuse
U On command four-wheel drive switch
V Gear motor
9 - 45

– +
EB803020
TROUBLESHOOTING
IF THE FOUR-WHEEL DRIVE INDICATOR LIGHT FAILS TO COME ON:
Procedure
Check:
1.Fuse (main, four-wheel drive) 5.Gear motor
3.Main switch (the entire 2WD/4WD selecting system)
4.On command four-wheel drive switch
NOTE:
1)Seat
2)Front carrier
3)Front fender
bleshooting.
EB802011
1.Fuse (main, four-wheel drive) NO CONTINUITY
EB802012
2.Battery
INCORRECT
CHAPTER 3.
CORRECT
3.Main switch INCORRECT
9 - 46

– +
*
C0NTINUITY
INCORRECT
4.On command four-wheel drive switch
CORRECT Replace the on command four-wheel

drive select switch.
5.Gear motor
● Check that the shift fork sliding gear is in
the 2WD position.
● Disconnect the gear motor coupler.
● Remove the gear motor from the differ-
ential gear case.
● Connect the battery (12 V) to the gear
motor terminals.
2WD → 4WD:
Brown/White terminal 1
Sky blue terminal 2
4WD → 2WD:
Sky blue terminal 2
Blue/Black terminal 3
● Make sure that the drive gear (shift fork
sliding gear) operates correctly.
NOTE: INCORRECT
When installing the differential gear
case in the gear motor, refer to “CON-
STANT VELOCITY JOINTS AND DIF-
FERENTIAL GEAR” in CHAPTER 7.
Replace the gear motor.
CORRECT
EB803028
6.Wiring connection
● Check the connections of the entire POOR CONNECTION
2WD/4WD selecting system.
Properly connect the 2WD/4WD selecting

system.
9 - 47

– +
ELEC
9 - 48

TRBL
SHTG 10
TRBL
SHTG
CHAPTER 10.
TROUBLESHOOTING
STARTING FAILURE/HARD STARTING ....................................................10-1

FUEL SYSTEM ....................................................................................10-1
ELECTRICAL SYSTEM ........................................................................10-1
COMPRESSION SYSTEM ..................................................................10-2
POOR IDLE SPEED PERFORMANCE .........................................................10-2

POOR IDLE SPEED PERFORMANCE .................................................10-2
POOR MEDIUM AND HIGH-SPEED PERFORMANCE ..............................10-2

POOR MEDIUM AND HIGH-SPEED PERFORMANCE .......................10-2
FAULTY DRIVE TRAIN ...............................................................................10-3
FAULTY GEAR SHIFTING ..........................................................................10-4

HARD SHIFTING .................................................................................10-4
SHIFT LEVER DOES NOT MOVE .......................................................10-4
JUMPS OUT OF GEAR .......................................................................10-4
FAULTY CLUTCH PERFORMANCE ...........................................................10-4

ENGINE OPERATES BUT MACHINE WILL NOT MOVE ...................10-4
CLUTCH SLIPPING .............................................................................10-4
POOR STARTING PERFORMANCE ...................................................10-4
POOR SPEED PERFORMANCE ..........................................................10-5
OVERHEATING ...........................................................................................10-5
OVERHEATING ...................................................................................10-5
OVER COOLING ..........................................................................................10-5

COOLING SYSTEM .............................................................................10-5
FAULTY BRAKE ..........................................................................................10-5

POOR BRAKING EFFECT ....................................................................10-5
SHOCK ABSORBER MALFUNCTION ........................................................10-6

MALFUNCTION ..................................................................................10-6

TRBL
SHTG
UNSTABLE HANDLING ..............................................................................10-6
UNSTABLE HANDLING ......................................................................10-6
LIGHTING SYSTEM ....................................................................................10-6

HEADLIGHT DARK ..............................................................................10-6
BULB BURNT OUT .............................................................................10-6

TRBL
STARTING FAILURE/HARD STARTING SHTG
TROUBLESHOOTING
NOTE:
The following troubleshooting does not cover all the possible causes of trouble. It should be
helpful, however, as a guide to troubleshooting. Refer to the relative procedure in this man-
ual for inspection, adjustment and replacement of parts.
STARTING FAILURE/HARD STARTING

FUEL SYSTEM
Fuel tank Carburetor
● Empty ● Deteriorated or contaminated fuel
● Clogged fuel filter ● Clogged pilot jet
● Clogged fuel strainer ● Clogged pilot air passage
● Clogged fuel breather hose ● Sucked-in air
● Deteriorated or contaminated fuel ● Deformed float
Fuel cock ● Worn needle valve
● Clogged fuel hose ● Improperly sealed valve seat
● Improperly adjusted fuel level
● Improperly set pilot jet
● Clogged starter jet
● Starter plunger malfunction
Air filter
● Clogged air filter element
ELECTRICAL SYSTEM
Spark plug Switches and wiring
● Improper plug gap ● Faulty main switch
● Worn electrodes ● Faulty engine stop switch
● Wire between terminals broken ● Broken or shorted wiring
● Improper heat range ● Faulty neutral switch
● Faulty spark plug cap ● Faulty start switch
Ignition coil ● Faulty rear brake switch
● Broken or shorted primary/secondary Starter motor

● Faulty spark plug lead ● Faulty starter motor
● Broken body ● Faulty starter relay
CDI system ● Faulty starter circuit cut-off relay
● Faulty CDI unit ● Faulty starter clutch
● Faulty pickup coil
● Broken woodruff key
10 - 1

STARTING FAILURE/HARD STARTING/POOR IDLE SPEED TRBL
PERFORMANCE/POOR MEDIUM AND HIGH-SPEED PERFORMANCE
SHTG
COMPRESSION SYSTEM
Cylinder and cylinder head Valve, camshaft and crankshaft
● Loose spark plug ● Improperly sealed valve
● Loose cylinder head or cylinder ● Improperly contacted valve and valve seat
● Broken cylinder head gasket ● Improper valve timing
● Worn, damaged or seized cylinder ● Broken valve spring
Piston and piston rings ● Seized camshaft
● Improperly installed piston ring ● Seized crankshaft
● Worn, fatigued or broken piston ring
● Seized piston ring
● Seized or damaged piston
POOR IDLE SPEED PERFORMANCE

POOR IDLE SPEED PERFORMANCE
Carburetor Electrical system
● Improperly returned starter plunger ● Faulty spark plug
● Loose pilot jet ● Faulty CDI unit
● Clogged pilot jet ● Faulty pickup coil
● Clogged pilot air jet ● Faulty ignition coil
● Improperly adjusted idle speed Valve train

(Throttle stop screw) ● Improperly adjusted valve clearance
● Improper throttle cable play Air filter

● Flooded carburetor ● Clogged air filter element
POOR MEDIUM AND HIGH-SPEED PERFORMANCE

POOR MEDIUM AND HIGH-SPEED PERFORMANCE
Refer to “STARTING FAILURE/HARD STARTING” and “POOR IDLE SPEED PERFORMANCE-
VALVE TRAIN”.
Carburetor Air filter
● Improper jet needle clip position ● Clogged air filter element
● Improperly adjusted fuel level
● Clogged or loose main jet
● Deteriorated or contaminated fuel
10 - 2

TRBL
FAULTY DRIVE TRAIN SHTG
FAULTY DRIVE TRAIN
The following conditions may indicate damaged shaft drive components:
Symptoms Possible Causes

1.A pronounced hesitation or “jerky” move- A.Bearing damage.
ment during acceleration, deceleration, or
sustained speed. (This must not be con- B.Improper gear lash.
fused with engine surging or transmission
characteristics.) C.Gear tooth damage.
2.A “rolling rumble” noticeable at low speed;
a high-pitched whine; a “clunk” from a D.Broken drive shaft.
shaft drive component or area.
3.A locked-up condition of the shaft drive E.Broken gear teeth.
mechanism, no power transmitted from
the engine to the front and/or rear wheels. F.Seizure due to lack of lubrication.
G.Small foreign objects lodged between the

moving parts.
NOTE:
Areas A, B, and C above may be extremely difficult to diagnose. The symptoms are quite sub-
tle and difficult to distinguish from normal machine operating noise. If there is reason to
believe these components are damaged, remove the components and inspect them.
10 - 3

FAULTY GEAR SHIFTING/ TRBL
FAULTY CLUTCH PERFORMANCE SHTG
FAULTY GEAR SHIFTING
HARD SHIFTING
Refer to “CLUTCH SLIPPING/DRAGGING-CLUTCH DRAGGING”.
SHIFT LEVER DOES NOT MOVE

Shift cam, shift fork Transmission
● Groove jammed with impurities ● Seized transmission gear
● Seized shift fork ● Jammed impurities
● Bent shift fork guide bar ● Incorrectly assembled transmission
Shift guide
● Broken shift guide
JUMPS OUT OF GEAR

Shift fork Shift cam
● Worn shift fork ● Improper thrust play
● Worn shift cam groove
Transmission
● Worn gear dog
FAULTY CLUTCH PERFORMANCE

ENGINE OPERATES BUT MACHINE WILL NOT MOVE
V-belt Transmission
● Bent, damaged or worn V-belt ● Damaged transmission gears
● V-belt slips
Primary pulley cam and primary pulley slider

● Damaged or worn primary pulley cam
● Damaged or worn primary pulley slider
CLUTCH SLIPPING
Clutch spring Primary sliding sheave
● Damaged, loose or worn clutch shoe ● Seized primary sliding sheave
spring
Clutch shoe
● Damaged or worn clutch shoe
POOR STARTING PERFORMANCE

V-belt Clutch shoe
● V-belt slips ● Bent, damaged or worn clutch shoe
● Oil or grease on the V-belt
Primary sliding sheave

● Faulty operation
● Worn pin groove
● Worn pin
10 - 4

FAULTY CLUTCH PERFORMANCE/OVERHEATING/ TRBL
OVER COOLING/FAULTY BRAKE SHTG
POOR SPEED PERFORMANCE
V-belt Primary sliding sheave
● Oil or grease on the V-belt ● Worn primary sliding sheave
Primary pulley weight Secondary fixed sheave

● Faulty operation ● Worn secondary fixed sheave
● Worn primary pulley weight Secondary sliding sheave

Primary fixed sheave ● Worn secondary sliding sheave
● Worn primary fixed sheave
OVERHEATING
OVERHEATING
Ignition system Engine oil
● Improper spark plug gap ● Improper oil level
● Improper spark plug heat range ● Improper oil viscosity
● Faulty CDI unit ● Inferior oil quality
Fuel system Brake

● Improper carburetor main jet ● Brake drag
(improper setting) Cooling system

● Improper fuel level ● Low coolant level
● Clogged air filter element ● Clogged or damaged radiator
Compression system ● Damaged or faulty water pump
● Heavy carbon build-up ● Thermostat stays closed
OVER COOLING
COOLING SYSTEM
Thermostat
● Thermostat stays open
FAULTY BRAKE
POOR BRAKING EFFECT
Disc brake
● Worn brake pads
● Worn disc
● Air in brake fluid
● Leaking brake fluid
● Faulty master cylinder kit cup
● Faulty caliper kit seal
● Loose union bolt
● Broken brake hose and pipe
● Oily or greasy disc/brake pads
● Improper brake fluid level
10 - 5

SHOCK ABSORBER MALFUNCTION/ TRBL
UNSTABLE HANDLING/LIGHTING SYSTEM SHTG
SHOCK ABSORBER MALFUNCTION
MALFUNCTION
● Bent or damaged damper rod
● Damaged oil seal lip
● Fatigued shock absorber spring
UNSTABLE HANDLING
UNSTABLE HANDLING
Handlebar Wheels
● Improperly installed or bent ● Deformed wheel
Steering ● Loose bearing
● Incorrect toe-in ● Bent or loose wheel axle
● Bent steering stem ● Excessive wheel runout
● Improperly installed steering stem Frame

● Damaged bearing or bearing race ● Bent
● Bent tie rods ● Damaged frame
● Deformed steering knuckles Swingarm

Tires ● Worn bearing or bushing
● Uneven tire pressures on both sides ● Bent or damaged
● Incorrect tire pressure
● Uneven tire wear
LIGHTING SYSTEM
HEADLIGHT DARK BULB BURNT OUT
● Improper bulb ● Improper bulb
● Too many electric accessories ● Faulty battery
● Hard charging (broken charging coil and/ ● Faulty rectifier/regulator
or faulty rectifier/regulator) ● Improperly grounded
● Incorrect connection ● Faulty main and/or lights switch
● Improperly grounded ● Bulb life expired
● Poor contacts (main or lights switch)
● Bulb life expired
10 - 6

YFM400FWA(M) WIRING DIAGRAM
1 CDI magneto
2 Rectifier/regulator
3 Main switch
4 Battery
A B C
5 Main fuse
G/W
Sb
G/L
Sb
O O
Br/W W
Sb L/B
W Br/W
L/B Sb
W/G W/L G/W L/Y Y/B G/Y Sb
6 Starter relay
L/R L/R
B
(BLACK)
B
(BLACK)
R/B B B R/B
W/R R W B
(BLACK)
R/W B/W O
(BLACK)
7 Starter motor
WIRE HARNESS SUB-WIRE HARNESS 2 WIRE HARNESS IGNITION COIL LEAD
(BLUE) (BLUE)
WIRE HARNESS SUB-WIRE HARNESS 1

8 Starting circuit cut-off relay
R R O B O
D
9 Ignition fuse
W/L
W/R
W/L
W/R
B B
0 Park switch
W/G R R W/G
W/G W/G
Y/B C E A Diode 1
W/R W/L W/L W/R R/W
B/W B Rear brake switch
W W L/Y L/Y
W W
1 W W 2 R
G/W
Sb W W F C CDI unit
W W B
W W W W
L/R
P O/R L/Y W
D Ignition coil
R R R G/Y
A
G/Y B
B
B/W B E Spark plug
B
W W
R
W
4 R R R
R G/Y
F Speed sensor
5 L/W L/B
(BLACK)
(BLACK)
L/R
A
G/Y
G Circuit breaker (fan motor)
B B
6
L/W
L/W
L/R
B B
H Thermo switch
B B L/B Y/B
8
0 (BLACK)
Br/L
I Fan motor
B
Y/B L/W
R/W R/W
G/Y B
B B
J Neutral indicator light
R B
B 7 R/W
(BLACK)
G K Reverse indicator light
3
R/W
B L Park indicator light
ON
OFF
B B/W
R Br
B/W B
Br/L R
M Reverse relay
R/W
R/B
N Reverse switch
Br/L
B
B/W C
O Neutral switch
9
R/B
P Diode 2
H Q Four-wheel drive indicator light
Br/L
R/B L
R Coolant temperature indicator light
L
(DARK GRAY)
S Thermo switch
A T Four-wheel drive fuse
Br/L Br/L Br/L Br/L
U On command four-wheel drive select switch
d Z X T
L/B
R/W R/W R/W
I L B B L V Gear motor
W/L L/B
JKL
W Four-wheel drive switch
Br R/Y P Br/R
Br/R W
P
Sb R/W
G/L R/W B
X Auxiliary DC jack fuse
Br Br
B/W Br/R R/W
R/W W/L L/R R/W
(BLACK)
C
B
Y Auxiliary DC jack
R/Y L/B Br/R
g Z Headlight fuse
B B
[ U Br L/R Br/W Br/R QR W/L Sb G/L L/R
\ ] B/W ` 2WD L/G B
L/B
B Sb
L/B
W Br/R
W/L R/W
R/W Sb
R/W G/L
G/L R/W
[ Handlebar switch (left)
L/B R/Y
G Y
Br R/W
Y G
OFF
LO
OFF
ON
OFF
PUSH
4WD
(BROWN) (BROWN)
R/W L/R
(BLACK)
\ Lights switch
B L L B
HI
Br/W B
W W/L
G/W B
] Engine stop switch
Sb L/B M R/W G/L _ Start switch
L Y G B P
W/L (RED)
Br
B G/W a Headlight
Y G W/B
C
C
C
C
b Taillight
OFF
ON
Br
B
Br
B
L
L S c Speedometer light
Y G Y G
P B
c b a a
B P B
Br/W
Sb
L/B
W
Sb
A
G/W
A
d Signal fuse
e L Sb G/L e Horn switch
B
B L
(GRAY)
L B
(GRAY) B
Y G Y G
V W f Horn
P B B B
g Hour meter (optional)
f B
B
G Y
B B
G Y O N Å For GB, F, CH, Oceania
B B L/B Br/W Sb
COLOR CODE
B............ Black W........... White G/Y ........Green/Yellow R/W....... Red/White
Br .......... Brown Y............ Yellow L/B .........Blue/Black R/Y ........ Red/Yellow
G ........... Green B/W ....... Black/White L/G.........Blue/Green W/B....... White/Black
L ............ Blue Br/L ....... Brown/Blue L/R .........Blue/Red W/G ...... White/Green
O ........... Orange Br/R ....... Brown/Red L/W ........Blue/White W/L ....... White/Blue
P............ Pink Br/W...... Brown/White L/Y .........Blue/Yellow W/R....... White/Red
R............ Red G/L ........ Green/Blue O/R ........Orange/Red Y/B ........ Yellow/Black
Sb ......... Sky blue G/W....... Green/White R/B.........Red/Black

Yfm400fwa 2000 5gh3ae1

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YFM400FWA(M ) 2000

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HOW TO USE THIS MANUAL

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I J K Illustrated symbols I to N in the exploded

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MACHINE IDENTIFICATION .........................................................................1-1

IMPORTANT INFORMATION .......................................................................1-3

CHECKING OF CONNECTIONS ...................................................................1-5

SPECIAL TOOLS ...........................................................................................1-6

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When the drive select lever is at the “L”,

When the stopper lever end 1 is not syn-

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Moisture → Dry each terminal with an air

Looseness → Bend up the pin 1 and con-

izer available at most part stores.

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Tool No. Tool name/How to use Illustration

Valve guide reamer (7.0 mm)

Gear lash measurement tool

Rotor holding tool

90890-01235 This tool is needed to hold the starter

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Piston pin puller

90890-01348 This tool is needed when removing or

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Gear lash measurement tool

Set Compression gauge set

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Clutch holding tool

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This tool is used to hold the shift cam.

Yamaha bond No. 1215

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HOW TO USE THE CONVERSION TABLE ................................................2-21

GENERAL TORQUE SPECIFICATIONS ......................................................2-21

LUBRICATION POINTS AND LUBRICANT TYPES ...................................2-22

COOLANT FLOW DIAGRAMS ...................................................................2-23

OIL FLOW DIAGRAMS ...............................................................................2-25

CABLE ROUTING ........................................................................................2-28

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YAMALUBE 4 (20W40) or SAE 20W40

YAMALUBE 4 (10W30) or SAE 10W30

-20° -10° 0° 10° 20° 30° 40° 50°C

Final gear oil SAE 80API “GL-4” Hypoid Gear Oil

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“A” head diameter IN 39.9 ~ 40.1 mm ----

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Valve seat width IN 1.2 ~ 1.4 mm ----

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